Note: Descriptions are shown in the official language in which they were submitted.
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FIBER MIX FOR YARN AND FABRICS
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The
present application claims the priority of
United States Patent Application No. 62/597,661, filed on
December 12, 2017, and incorporated herein by reference.
FIELD OF THE APPLICATION
[0002] The
present application relates to yarns used in
textiles and fabrics having flame-resistant properties.
BACKGROUND OF THE ART
[0003]
Textiles have evolved drastically for uses in
various applications, in which the technical features of the
textile perform different protective functions. For instance,
textiles may be flame-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.
[0004] 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.
Moreover, it is desired that fabrics made of protective yarns
emulate as much as possible other known types of fabrics, such
as denim.
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.
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SUMMARY OF THE APPLICATION
[0005] It is therefore an aim of the present invention to
provide novel fiber mix for yarn.
[0006] Therefore, in accordance with a first embodiment of
the present application, there is provided a yarn comprising:
a blend of at least two types of fibers, including at least
fibers of viscose incorporating silica composing 50-85% by
weight of the yarn, and fibers of modacrylic composing 15-50%
by weight of the yarn.
[0007] Further in accordance with the first embodiment, the
fibers of viscose have a linear mass density ranging between
1.5 and 3.5 deniers, inclusively.
[0008] Still further in accordance with the first
embodiment, the fibers of viscose are for instance staple
fibers of viscose.
[0009] Still further in accordance with the first
embodiment, a substantial portion of the staple fibers are for
instance between 35 mm and 120 mm in length.
[0010] Still further in accordance with the first
embodiment, the fibers of modacrylic have for instance a
linear mass density ranging between 1.0 and 3.0 deniers,
inclusively.
[0011] Still further in accordance with the first
embodiment, the fibers of modacrylic are for instance staple
fibers.
[0012] Still further in accordance with the first
embodiment, a substantial portion of the staple fibers of
modacrylic are for instance between 35 mm and 120 mm in
length.
[0013] Still further in accordance with the first
embodiment, the blend of fibers has for instance a fiber-to-
fiber dispersion of the fibers.
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[0014] Still further in accordance with the first
embodiment, fibers of meta-aramid compose for instance at most
20% by weight of the yarn.
[0015] Still further in accordance with the first
embodiment, fibers of para-aramid compose for instance at most
20% by weight of the yarn.
[0016] Still further in accordance with the first
embodiment, fibers of nylon compose for instance at most 20%
by weight of the yarn.
[0017] Still further in accordance with the first
embodiment, a yarn count is for instance between 20 tex and
250 tex, inclusively.
[0018] In accordance with a second embodiment of the
present application, there is provided a composite yarn
comprising: a core, the core being defined by the yarn as
described above; and a sheath surrounding the core.
[0019] Further in accordance with the second embodiment,
the sheath includes cellulosic fibers.
[0020] Still further in accordance with the second
embodiment, the sheath includes cotton fibers, lyocell or
viscose fibers.
[0021] Still further in accordance with the second
embodiment, the sheath is for instance 100% cotton fibers.
[0022] Still further in accordance with the second
embodiment, the cotton is for instance non-treated.
[0023] Still further in accordance with the second
embodiment, the sheath includes for instance nylon fibers.
[0024] Still further in accordance with the second
embodiment, the sheath has for instance fibers of corespun
around the core.
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DESCRIPTION OF THE DRAWINGS
[0025]
Fig. 1 is a table illustrating fiber mixes of a yarn
according to the present disclosure; and
[0026]
Fig. 2 is a schematic view of the yarn of Fig. 1
with a sheath thereon, in accordance with an embodiment of the
present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The
present application pertains to a yarn and to a
fiber mix (a.k.a., fibre mix) used for a yarn in accordance
with the present disclosure. Referring to Fig. 1, the fiber
mix in accordance with the present disclosure comprises two or
more fiber types that concurrently provide particular
properties to the yarn of the present disclosure. Moreover, a
textile made of the yarn has a texture and feel emulating that
of denim. The yarn of the present disclosure has a blend of
fibers 10 and 20. The blend may include other fibers, such as
fibers 30 and/or 40 in the table of Fig. 1. According to an
embodiment, the fibers 10, 20, 30 and/or 40 are staple fibers,
i.e., discrete fiber segments.
[0028]
Fiber 10 in Fig. 1 is present in a ratio ranging
between 50% and 85% by weight of the yarn, and is viscose that
incorporates silica. The incorporation of polysilicic acid
into the cellulosic structure of viscose enhances the fire
resistance of the hybrid fiber by distinct mechanisms, such as
by the formation on the fiber surface of an inherently
incombustible char of silica residue, and by a lowering of the
temperature at which water is released from the fiber. The
fiber 10 may be viscose FR (fire resistant). In
an
embodiment, the fibers 10 of viscose are staple fibers of
viscose with silica. The staple fibers 10 may have a linear
mass density ranging between 1.5 and 3.5 deniers, inclusively,
though the linear mass density may be more or less. The staple
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fibers 10 may have a linear density of 1.66 to 3.89 grams per
10,000 meters, in an embodiment, but it may be outside of this
range as well in other embodiments. The staple fibers 10 may
have a diameter between 11.5 pm and 17.6 pm, inclusively, also
with the possibility of being more or less. In the case of
staple fibers, the fiber length of an individual fiber 10 of
viscose is between 35 mm and up to 120 mm. Some fibers 10 may
be out of this range, for example a proportion of the fibers
may be longer or shorter.
[0029]
Fiber 20 in Fig. 1 is present in a ratio ranging
between 15% and 50% by weight of the yarn. In an embodiment,
fiber 20 is modacrylic (e.g., composed of less than 85% and
more than 35% by weight of acrylonitrile units). In an
embodiment, the fibers 20 of modacrylic are staple fibers.
The staple fibers 20 may have a linear mass density ranging
between 1.0 and 3.0 deniers, inclusively, though the linear
mass density may be more or less. The staple fibers 10 may
have a linear density of 1.10 to 3.30 grams per 10,000 meters,
in an embodiment, but it may be outside of this range as well
in other embodiments. The staple fibers 20 of modacrylic may
have a diameter ranging inclusively between 9.5 pm and 17.0
pm, also with the possibility of being more or less. In the
case of staple fibers, the fiber length of an individual fiber
of modacrylic is between 35 mm and up to 120 mm. Some
fibers 20 may be out of this range, for example a proportion
of the fibers 20 may be longer or shorter.
[0030]
According to an embodiment, the fiber mix of the
yarn has only these two fibers, with the viscose with silica
constituting between 50% and 85% of the weight of the yarn,
and the modacrylic forming the balance of the weight. This is
shown in blend A, blend B and blend I in Fig. 1, with viscose
to modacrylic ratios of 85:15, 70:30, and 50:50, respectively.
[0031] The
combination of these fibers 10 and 20 creates a
synergy that increases the flame-resistance performance of
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each of these fibers, in comparison to if they were used
alone. A
yarn of these two fibers in the above-referred
ratios, with or without additional fibers, responds well to
various flame-resistance tests like Vertical flame and Flash
Fire Manikin. Once submitted to an open flame, a fabric woven
from the yarn as above does not burn, melt nor drip in the
time delays according to the NFPA 2112 standard. The fabric
integrity is well preserved in comparison to other flame-
resistant fabrics, i.e., the fabric does not crack, and holes
do not appear when submitted to an open flame for 3 seconds.
[0032] The
fibers 10 and 20 must be well distributed inside
the yarn so that the synergy of the blend works at an optimal
level. The blend of modacrylic and viscose (e.g., viscore FR)
is done in such a way that the dispersion of the two fibers is
said to be fiber-to-fiber (a.k.a., fibre-to-fibre), at the
staple fiber level. According to an embodiment, the two fibers
and 20 may be combined early in the manufacturing process
of the textile yarns, before the spinning itself, for instance
at the carding process (intimate blend) or at the drawing
process (draw blend). If
properly fabricated, a fabric made
from the
yarn may comply with the NFPA2112-2012 Standard,
i.e., Standard on Flame-Resistant Garments for Protection of
Industrial Personnel Against Flash Fire.
[0033] It
is also possible to incorporate a third
component, a fourth component, etc, in the yarn to provide
additional functionality to the yarn and textile. For
instance, additional functionalities include increasing the
resistance to washing (abrasion resistance), increasing the
strength of the fabric and/or increasing protection to fire.
As shown in Fig. 1, the fibers 30/40 may not exceed 20% of the
total yarn weight, while silica-containing viscose at fiber 10
is present at 50% or above by weight. In some embodiment, the
fibers 30/40 may exceed 20% of the total yarn weight.
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[0034]
Fiber 30 in Fig. 1 may be present in a ratio ranging
between 0% and 20% by weight of the yarn. The
fiber 30 is
meta-aramid, para-aramid or aramid-type fiber. The
meta-
aramid fiber (e.g., Nomexn, Conexg) may be used to increase
the yarn tenacity without affecting the fire retardant
property of the yarn. Alternatively, the aramid-type fiber is
a para-aramid (e.g., KevlarED, Twaron(0) that increases the
tensile strength of the yarn. Both the para-aramid fibers and
meta-aramid fibers could be greige (dyeable) fibers or dope
dyed fibers. It
is also considered to use raw fiber dying,
dope dying before extrusion or greige. When the fiber 30 is a
dope-dyed or fiber-dyed meta-aramid, other fibers in the yarn
may be dyed using atmospheric pressure without affecting the
fire protection of the fabric.
[0035] The
staple fibers 30 of meta-aramid and/or para-
aramid may have a linear mass density ranging between 1.0
deniers and 3.0 deniers inclusively, though the linear mass
density may be more or less.. The staple fibers 30 of meta-
aramid may have a linear density of 1.10 to 3.30 grams per
10,000 meters, but it may be outside of this range as well in
other embodiments. The staple fibers 30 of meta-aramid may
have a diameter ranging inclusively 10.1 pm and 17.6 pm. The
fiber length of an individual fiber of meta-aramid is between
35mm up to 120 mm.
[0036]
Fiber 40 in Fig. 1 is present in a ratio ranging
between 0% and 20% by weight of the yarn, and is nylon. Nylon
may be used to increase the yarn tenacity, resistance to
abrasion, without affecting the fire retardant property of the
yarn. Although not shown in Fig. 1, the yarn may have both
fiber 30 and fiber 40 in a combined total weight in a ratio
ranging between 0% and 20% by weight of the yarn. In another
embodiment, the fourth component is an anti-static fiber.
[0037] In
an embodiment, the fibers 40 of nylon are also
staple fibers. The
staple fibers 40 may have a linear mass
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density ranging between 0.9 and 3.25 deniers, inclusively,
though the linear mass density may be more or less. The staple
fibers 40 may have a linear density of 1.0 to 3.3 grams per
10,000 meters, in an embodiment, but it may be outside of this
range as well in other embodiments. The staple fibers 40 of
nylon may have a diameter ranging inclusively between 10.6 pm
and 20.1 pm, also with the possibility of being more or less.
In the case of staple fibers, the fiber length of an
individual fiber 40 of nylon is between 35 mm and up to 120
mm.
Some fibers 40 may be out of this range, for example a
proportion of the fibers 40 may be longer or shorter.
[0038] The
addition of the fibers 30 and/or 40 to the
fibers 10 and 20 may also be done at the staple fiber level
using intimate blending for a fibre-to-fibre combination of
the staple fibers.
[0039] The
yarn may be woven or knitted into various
fabrics. In a non-limitative embodiment, the yarn has a twill
weaving to emulate a denim fabric. In particularly, the weft
is weaved to pass under two or more warp threads to resemble
denim.
Accordingly, with appropriately dyed yarn and
appropriate twill weaving, a textile made of the yarn as above
may be similar to a denim in feel and look, while procuring
effective protection against flash fire and flame to the
wearer.
Moreover, a fabric made using the yarn provides
suitable protection against heat transfer and against
electrical arcs.
[0040]
Textiles made with the yarn 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.
[0041] The
yarn count for the yarn of Fig. 1 constituted as
described above may be between 20 tex and 250 tex. A textile
made of the yarn 10 may have the properties described above
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when woven with a surface weight ranging between 4.5 and 25.0
ounces per square yards.
[0042]
There may be numerous applications for textiles
featuring the yarn. As a non-exhaustive, exemplary list, the
yarn 10 may be used as part of woven coveralls for the oil and
gas industry (NFPA 2112 compliant), construction garment
(woven), electrician pants (woven), fireproof partition
(woven), military and workers fire-resistant underwear
(knitted), fire-resistant socks for military and workers
(knit), textile fireproof barrier for foam mattress (knitted
or woven).
[0043] It
is contemplated to use the yarn of Fig. 1 in a
sheath surrounding a core. For example, referring to Fig. 2,
another embodiment of the present disclosure is shown, in
which the yarn with blends according to Fig. 1 is used as a
core 51 of a composite yarn 50. In the composite yarn 50, a
sheath 52 surround the core 51. The sheath 52 may be made of
any material. According to an embodiment, if the textile made
from the composite yarn 50 is to emulate denim, the sheath 52
is cotton, such as 100% cotton. For
example, the cotton of
the sheath 52 may be traditional non-treated cotton fibers.
Other cellulosic fibers may be used, including viscose, to
form the sheath 52. All such fibers may be staple fibers. It
is contemplated to blend in other fibers as well, to make up
the sheath 52. For
example, there may be between 0-20% of
another fiber in a blend of the yarn of the sheath 52, such as
nylon.
[0044] It
is contemplated to add the sheath 52 onto the
core 51 by way of a corespun technique, using cotton fibers.
Consequently, the composite yarn 50 has a core 51 with one or
more yarns or fibers twisted around the core 51. More
specifically, the yarn as in Fig. 1 is spun, and is made of a
blend the viscose fibers 10/modacrylic fibers 20 with or
without meta-aramid and/or para-aramid fibers 30 and/or nylon
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fibers 40. Once the blended yarn is spun, for example as a
first step, this blended yarn may be used as a core 51 to be
introduce in a core spinning process as a second step to spin
around this initial yarn 51 a sheath 52 of cellulosic fiber
(as cotton, lyocell, or viscose). This process is done in such
a way to have the sheath 52 of cellulosic fibers at the
surface of the yarn/core 51, whereby the dyeing of the
exterior of cellulosic fiber may be achieved in any color that
would be required. It is understood that the ratio sheath
52/core yarn 51 would be more than 1Ø In other words, the
linear weight of the sheath should be 50% and more, with the
sheath 52 covering up completely the core yarn 51.
[0045] According to an embodiment, the sheath 52 made of
cellulosic fiber may participate in a chemical reaction under
flame with the modacrylic and Viscose FR degradation, so as to
inhibit the fire reaction and stop the flame from spreading
into a fabric made of the composite yarn 50.
[0046] For example, one embodiment of the composite yarn 50
would be a yarn as in Fig. 1 made of 60% viscose FR staple
fibers 10; 30% modacrylic staple fibers 20; 10% meta-aramid
staple fibers 30 in a linear weight of 32.8 tex. Once yarn to
serve as the core 51 is spun using any spinning technology
(either air jet spun with intermingling, vortex spun, open-end
spun, ring spun or friction spun, or Worsted spun), it is fed
to a core spinning machine to become the core 51 of a yarn
where a sheath of cotton is spun around it.
[0047] Again, by way of example, by adding 40.7 grams/1000
meters of cotton fibers to the surface of the yarn in the core
51, the composite yarn 50 is created, with for example a blend
ratio of 55.4% cotton (outer sheath 52), 26.7% viscose FR,
13.4% modacrylic and 4.5% meta-aramid in the core 51. These
proportions can each vary. The composite yarn 50 may have a
linear weight of 73.8 tex 10%.
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[0048] The
blended yarn without the cellulosic sheath 52,
as in Fig. 1 (i.e., the core 51 alone), may have a linear
weight ranging between 20 tex and 255 tex. It is understood
that this type of yarn could be produce and use as single
yarn, like 20.0 tex (30/1Ne) or by twisting many ends of a
single yarn together, such as in 85X3tex (6.9/3Ne). The
construction of the yarn (single or multiple ply) would be as
a function of the fabric strength required and/or fabric
construction desired by the knitter or weaver.
[0049] The
composite yarn 50 may have a higher linear
weight because of the addition of the sheath 52. Thus, the
linear weight of a yarn 51 with a cellulosic sheath 52 would
be between 40 tex and 400 tex, inclusively. The
composite
yarn 50 could be produced and used as single core spun yarn,
e.g., 40.0 tex (14.8/1Ne) or by twisting many ends of a single
yarn together like 196.8X2tex (3/2Ne). The construction of the
yarn (single or multiple ply) may be determined as a function
of the fabric strength required and/or fabric construction
desired by the knitter or weaver.
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