PROTECTIVE YARNS AND FABRICS MADE WITH ALTERNATING FIBROUS BLENDED ROVINGS

Abstract

A method and system for forming protective composite yarns and fabrics having selected performance characteristics including cut resistance and/or fire/heat resistance, while also providing enhanced comfort and aesthetic attributes. The yarn will include fibers of a first type introduced from a first roving to a first set of drafting rollers of a spinning frame, and one or more additional types of fibers introduced from one or more additional rovings additional sets of drafting rollers of the spinning frame in an alternating fashion with the fibers of the first type. The fibers of the first type and the fibers of the additional type are substantially overlapped and successively attached and detached to form the composite yarn having attributes of the first fibers, such as increased comfort, moisture-wicking and an ability to be dyed, colored or printed, combined with technical properties of the fibers of the one or more additional types of fibers, such as cut, abrasion and/or fire/heat resistance, static dissipation, and other performance characteristics, with bands or splashes of color from such fibers incorporated therein. Fashionable or aesthetically appearing performance fabrics can be formed from the composite yarn with the desired performance and comfort characteristics.

Description

TECHNICAL FIELD

The present invention relates to fabrics, yarns and processes for making yarns with selected or desired performance properties. In particular, the present invention relates to composite yarns made with alternating fibrous rovings, and a process of forming such yarns incorporating desirable performance characteristics, such as enhanced strength, heat protection and cut-resistance, while further having enhanced comfort and an aesthetically pleasing appearance, enabling the protective performance fabrics formed from such yarns to have a fashionable look.

BACKGROUND

High performance apparel may be designed with desired physical properties, such as cut-resistance, increased strength, and thermal/fire-resistance properties, but may lack in other properties, such as aesthetics, including varying color choices, comfort, moisture wicking, and so on. In the manufacture of protective apparel, manufacturers generally rely on blending different levels and percentages of technical fibers as they spin performance yarns used to manufacture such garments to obtain particular properties for the intended garment's functional end use (i.e., for a electrical workers arc protection or oil field employee protection, etc. . . . ). In blending such performance yarns, properties of various fibers in the blend typically are evaluated to complement one another from a functional or physical property perspective. Maintaining accurate fiber or blend percentages along with consistent yarn weight is critical in ensuring performance levels of the fabric or garment. However, while such homogeneous blends generally are designed to produce fabric with desired uniform performance properties, they often have an unstylish appearance.

For example, para-aramid fibers have heat and cut protection, but have limited color options. Moreover, dyeing of para-aramid and other aramid fibers is difficult, and garments made of para-aramid, meta-aramid and other aramid fibers are typically somewhat uncomfortable to wear. In contrast, garments made from 100% cotton are extremely comfortable to wear but provide minimal cut or heat protection. Similarly, fire resistant rayon provides comfort and fire resistance to a fabric but provides very low cut resistance and poor abrasion resistance, and shrinks when exposed to high temperature, thereby making it ineffective for certain high heat applications such as needed in the petroleum industry. Other fibers, such as oxidized polyacrylonitrile (“Opan”) fibers provide good heat resistance, but are only black in color, have poor fiber strength, and typically add little to no cut protection to a garment. Hence, there is a need for protective apparel to achieve a blend of high performance characteristics provided by high performance fibers such as para-aramids with the comfort and dyeing characteristics provided by other types of fibers such as cotton.

Fabrics with splashes of other colors or shades have been made in the past using yarns incorporating fibers of variable lengths, and reducing carding the mechanism at the carding operation so that the fibers in the resultant yarn are massed together and not intimately blended or uniformly distributed within the yarn mass. For example, Mosaic® yarns having fibers of various colors have been produced using a Mosaic Attachment from Pinter Caipo. In addition, fibers of various colors may be inserted in the fiber mass during carding, for example, by incorporating a regenerated shoddy fiber as a percentage in the fibrous blend initially at the start of processing before carding. However, these techniques have not been pursued for producing technical/high performance yarns for use in protective fabrics requiring enhanced heat/fire, cut and/or abrasion resistance properties because the shorter or pre-spun fibers or the clumps of uneven fibers used/formed in such yarns can cause significant weak spots in the yarn, or yarn weight variation thereby compromising the consistency of the required strength or other protective qualities of performance protective garments.

Accordingly, it can be seen that a need exists for blended yarns having enhanced performance characteristics provided by fibers of high performance fibers but which also include increased comfort and dyeing characteristics.

SUMMARY

Briefly described, the present disclosure is, in one aspect, directed to methods and systems for forming composite yarns with desired performance, wearability and aesthetic or fashion characteristics or attributes. In an embodiment, a method for forming such a composite yarn is provided, including introducing fibers of a first type from a first roving to a first set of drafting rollers of a spinning frame. The first type or base fibers can include natural or synthetic/polymeric fibers, including staple fibers such as cotton, wool, modacrylic, rayon, nylon, etc. . . . , having selected properties such as moisture wicking, softness, comfort to wear, etc., and which fibers further generally will include fibers that also generally are susceptible to being dyed, printed or colored. During the spinning process, fibers of one or more additional types of fibers will be selectively introduced into the spinning process at a set of drafting rollers, for example, by alternating between fibers fed from one or more different rovings or other sources. The additional type(s) of fibers typically will include technical or performance fibers formed from materials selected to provide enhanced heat and/or cut or abrasion resistance, and/or for static dissipation and other performance or technical properties (e.g., aramids, para-aramids, polyacrylonitrile, etc.), but which technical fibers generally are limited in colors and/or are generally resistant to dyeing, coloring or printing.

Selectively alternating the feeding of one or more fibers from the different rovings during the spinning enables a substantially non-homogeneous blending of the fibers at the intersection points where the fibers from the different rovings are introduced to the fibrous yarn bundle during spinning to form composite yarns having different types of fibers incorporating different performance properties. The composite yarns further generally will be spun with a substantially consistent weight and will display a blend of characteristics or attributes of the first type of fibers and the one or more additional type of fibers, combining technical or performance properties such as fire and/or cut resistance, and static dissipation, of the selected technical fibers, such as aramids, Opan, polyethylene, etc., to create comfortable performance/protective fabrics that are also fashionable. For example, the yarns can be knitted or woven to form soft, flexible fabrics with heat, cut and/or abrasion resistance, but which also have an aesthetically pleasing or fashionable appearance, and can include an ability to be dyed to create fabrics in different colors and/or incorporate other patterning effects.

In an embodiment, the fibers of the first type and the fibers of one or more additional types are fed from a base roving and from an additional, different roving to the spinning frame in an alternating fashion. In other embodiments, the composite yarn can be spun using fibers fed from two, three or more roving sources. As a result of the controlled, alternating feeding of fibers, at the points of intersection between the different fibers fed from the different rovings, during a change-over as the feeding of fibers is alternated between the rovings, the fibers of the first type are overlapped and blended with the one or more additional types of fibers (e.g. the technical fibers) so as to be integrated into the fibrous yarn bundle being spun, successively attaching and detaching the first type of fibers and the fibers of the one or more additional type fibers as they are moved through the spinning frame, which can help avoid breaks and/or weak spots in the finished composite yarn.

For example, the feeding of the first type fibers from a first roving to the spinning frame will be controlled and can be selectively stopped or interrupted while fibers from a second roving are fed into the spinning frame. The speed of the rollers of the spinning frame feeding the fibers from the different rovings and the timing of which the fibers are fed from the rovings can be controlled as needed to control or balance the amount/length of technical fibers blended into the yarn to provide desired technical characteristics with a level of softness and feel of the composite yarns based on fabric requirements. As the feeding of the first roving is interrupted, the second roving can be coincidentally started so as to feed its fibers to the spinning frame substantially immediately and/or without a substantive delay in the supply of fibers entering the spinning frame; thus enabling a minimizing of the blending/integrating of the fibers of the first roving with the fibers of the second roving to the points of intersection to maintain the strength and overall structural integrity of the composite yarn, while applying discrete lengths of the technical fibers throughout the yarn to incorporate the structural support and other technical properties thereof, and adding splashes of color or other patterning effects.

In one aspect, the process described above can produce a ring spun yarn comprising a composite blend of fibers or fibrous blends from different rovings alternatively fed and blended at points of intersection. Controlling the selective, alternating feeding of the fibers results in a composite yarn that generally is smooth in spite of the transitions between different rovings and which generally will be formed with a substantially consistent fiber weight per length. Moreover, controlling and limiting the transitions between rovings avoids producing a weakness in resultant fabrics made from the composite yarns. Thus, the composite yarns formed by the disclosed process of alternating between rovings of different fibers or fiber blends can be used to produce lightweight fabrics that will incorporate various technical/performance characteristics, such as enhanced strength, abrasion and fire resistance, etc. . . . , but which will be comfortable, flexible and which can be provided with various desired patterning effects, such as splashes or bands of colors and/or an ability for the yarns/fabrics to be dyed, printed or otherwise colored, by incorporating high performance fibers of various colors or shades into the aesthetic look and/or patterning of the fabrics. As a result, more causal, fashionable and wearable garments can be made from the resulting fabrics, while garments are also provided with enhanced structural support and other desired protective properties integrated therein.

In one aspect, some technical fibers can be used to create accent color(s) and/or various pattern effects in protective fabrics, such as for use in forming underlayment type garments for military use and first responders, which fabrics also will have enhanced technical properties, such as heat resistance, fire resistance or cut/abrasion resistance that are substantially consistent throughout the fabric. By way of a further example, garments made of 100% para-aramid fibers are usually yellow in color and typically are resistant to dyeing, and generally also are uncomfortable to wear. When used as an accent fiber in a composite yarn as one of the alternating roving fibers selectively integrated with fibers from a first roving such as cotton, modacrylic, or similar staple fibers or blends thereof, the resultant composite yarn can be woven or knitted to form a decorative performance fabric with splashes of color patterned therein. The bands or splashes of technical fibers in the resultant fabric, in addition to adding such splashes of color, will also provide structure/support to the fabric, as well as a reduction in heat shrinkage, an increase in strength of the fabric and provide greater structural stability, while the base fibers provide attributes such as comfort, flexibility and overall aesthetic appearance.

The fibers from each roving may be selectively introduced to the drafting rollers of a spinning frame and the drafting zone may be switched from one roving to another to feed without substantial interruption or delay in the flow of fibers into the drafting zone under control of a control system for the spinning frame and associated control logic programmed by a user. This allows small splashes of various different colored technical/performance fibers of one roving or to be selectively blended into yarn composition, to provide a desired or selected fashionable look with increased desired or needed performance capabilities and properties that are substantially homogeneous throughout the fabric. In some embodiments, the switchover between rovings can be accomplished with in about 10 cm or less, and in some embodiments, in as low as about 1 cm or less, though varying change-over lengths also can be used, to enable the yarn count to stay substantially consistent per industry performance apparel certifications and to ensure adequate yarn strength at the splicing or joining of the two rovings.

Various objects, features and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detail description, when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

It will be appreciated that for simplicity and clarity of illustration, elements illustrated in the Figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements. Embodiments incorporating teachings of the present disclosure are shown and described with respect to the drawings herein, in which:

FIG. 1A is a schematic illustrations of a system and a method for making a composite performance yarn, according to embodiments of the disclosure;

FIG. 1B is a schematic illustration of an embodiment of drafting rolls and drafting zone of a spinning frame as shown in FIG. 1A for producing the composite performance yarn.

FIG. 2 is a flowchart illustrating a method for making a composite performance yarn, according to an embodiment of the disclosure.

FIGS. 3A-3C illustrate examples of fabrics formed with the composite performance yarns according to the principles of the present disclosure.

The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

The following description in combination with the Figures is provided to assist in understanding the teachings disclosed herein. The description is focused on specific implementations and embodiments of the teachings and is provided to assist in describing the teachings. This focus should not be interpreted as a limitation on the scope or applicability of the teachings.

In general, the present invention is directed to systems and methods for formation of protective composite yarns and fabrics made from such blended yarns. These composite yarns generally exhibit properties such as enhanced cut-resistance and strength along with comfort, moisture-wicking, and other characteristics. Some of the embodiments of the present disclosure contain processes that help impart useful performance and comfort properties to the finished composite yarns. These performance and comfort properties will further be imparted to fabrics made of such composite yarns and the garments formed therefrom. In addition, the composite yarns of the present invention are designed to be produced using a ring or other type of spinning frame and spinning process. It is to be noted that the term yarn is used to indicate a combination of fibers, threads or filaments.

The finished composite yarns formed by the processes described herein generally can be knitted or woven without sustaining substantial physical damage and good processability during knitting or weaving of the yarns tufting, etc. . . . for forming various woven and/or non-woven fabrics. The resultant fabrics formed from the composite yarns will have enhanced selected performance properties, such as increased strength, cut-resistance and fire/heat resistance, but also will possess desired levels of comfort, flexibility and durability, and further will be provided with colored patterning effects, such as splashes or bands of color, and further will have the ability to be dyed, colored and/or printed in a variety of colors and/or incorporate various other pattern effects to create a fashionable performance fabric.

Such fabrics can be used in forming protective garments or other articles such as coverings, awnings, etc. For example, fabrics formed from the yarns produced according to the present disclosure can be used for underlayment type garments such as T-shirts to be worn under other protective clothing such as military uniforms, electrical arc protection, or a variety of other type of garments and articles. Such garments or other articles thus can be made with desired technical/performance properties such as cut resistance, impact resistance, enhanced strength, and fire or heat resistance incorporated therein, but will have a softness, feel and flexibility sufficient to enable enhanced mobility and/or wearability, while also allowing the garment to be dyed, printed and/or colored or otherwise formed or provided with an aesthetically pleasing and fashionable appearance. As a result, the wearer of such a garment can have protection from contact with potentially abrasive or cutting materials and/or fire/heat, in a comfortable and fashionable product.

FIGS. 1A-1B illustrate embodiments of a system and process for making a blended or composite yarn 120, in accordance with the present disclosure. Fibers of a base or first series or type 15 are introduced from a first or base roving 12 to a first set of drafting rollers 18 of a first drafting zone 16A of a spinning frame 20 where the first fibers 15 will be spun. An additional or second type or series of fibers 115 also will be selectively fed from a second or additional roving 112 (FIG. 1) via a second set of drafting rollers 118 of a second drafting zone 16B of the spinning frame. In one example arrangement as shown in FIG. 1B, the drafting rollers can be arranged in a staggered arrangement with the second set of drafting rolls 118/second drafting zone 16B upstream from the first set of drafting rolls 18/first drafting zone 16A. The fibers 15/115 will be fed from each of their rovings 12/112 (FIG. 1A) in a controlled, alternating fashion to a front drafting zone 17 of the spinning frame 20 to create a controlled blending of the different fibers at the points of intersection therebetween created by the change-over from one roving to the other.

It is also possible to introduce still further additional fibers, (which can be of the same or similar type or different types or blends of fibers) as the additional fibers or the first/base fibers 15, fed from a series of rovings, e.g., two-three rovings or more to the spinning frame 20. The spinning frame 20 may form a part of a ring spinning assembly/process, an or other spinning process that incorporates a 4-6 roll drafting system or assembly; and, as indicated in FIGS. 1A-1B, the fibers of the first and second types will be blended and spun during the spinning process, forming a composite yarn of alternating, discrete lengths of differing fibers without a core filament.

The fibers of the base or first type of fibers 15 can be composed of one or more materials selected based upon desired characteristics or properties. For example, the first fibers 15 can include staple fibers selected for comfort, softness, feel, and/or ease of dyeing, printing or coloring. The first type or base fibers 15 can comprise fibers of cotton, rayon, nylon, modacrylics, and/or blends thereof. In some embodiments, the first type fibers 15 may include 100% rayon or 100% cotton fibers that, in a resultant fabric, provide increased comfort, softness and/or wearability. In other embodiments, the first fibers 15 may include a fibrous blend of, for example, cotton and modacrylics, or other blends of natural or synthetic fibers of varying weight percentages.

Fibers of one or more additional type(s), as indicated by second fibers 115, will be introduced to the spinning frame 20 from at least one additional roving 112 as indicated in FIG. 1A. The additional type(s) of fibers 115 will be fed through the additional set(s) drafting of rollers 118 of the spinning frame 20 in an alternating fashion; being introduced to the front drafting zone 17 as the feeding of the fibers 15 of the first roving is interrupted. The second fibers 115 generally can be include technical or performance fibers of materials selected to provide certain desired technical or performance characteristics, such as, cut-resistance, abrasion resistance, flame/fire resistance, and/or static dissipation properties.

The fibers of the one or more second or additional types 115 can comprise technical or performance fibers including materials selected from a group including, para-aramids, Meta-aramids, modacrylics, Oxidized Polyacrylonitrile (“Opan”), high density polyethylene such as Vectran™, polyphenylene sulfide (PPS), kynol, polybenzimidazole (PBI), polybenzoxazole (PBO), fire resistant nylon, fire resistant polyester, polyvinyl alcohol (PVA), fire resistant rayon, cotton, polyester, acrylic, nylon 6/6.6 and Fr nylon, static dissipation fibers such as P84® polyimide fibers, and blends thereof. Such fibers also can be used as the base fibers, alone or as a blend with fibers such as cotton, wool, etc. . . . These ranges can include up to about 100% of one type performance fiber to percentages as low as about 2%-5%. For example, the second or additional fibers 115 may include 100% para-aramid fibers or other fibers having inherent enhanced heat and/or cut or abrasion resistance properties, but which generally are limited in colors, are difficult to dye, and are typically reduce comfort and/or wear ability of garments made therefrom.

The selection of the fibers 15 (e.g., base fibers) and the one or more second or additional (e.g., technical) fibers 115 may be based on achieving certain specific characteristics in the composite yarn. By way of example, technical fibers 115 may include oxidized polyacrylonitrile (“Opan”), which has a high heat resistance, but generally is limited to black color, has limited fiber strength and thus adds minimal cut protection to resultant yarns and garments. When technical fibers containing Opan are combined with base or staple fibers 15 such as cotton, nylon, etc. . . . , in a manner such as illustrated in FIGS. 1A-1B, the blended yarn and fabric may exhibit enhanced heat resistance and reduced heat shrinkage along with a unique color blend, such as illustrated in the sample fabrics shown in FIGS. 3A-3C.

Similarly, the base fibers 15 may include fire-resistant rayon, which provides comfort and fire resistance generally but has low cut resistance, poor abrasion resistance, and shrinks when exposed to high temperatures, thereby making it generally ineffective for certain high heat applications such as required in the petroleum industry. Such fibers may be blended with other fibers, such as Meta-aramid fibers that have good heat resistance but limited cut protection qualities and generally are uncomfortable in a garment. These fibers further may be combined with additional technical fibers that also have heat resistance properties and that are also comfortable to wear in the resultant fabric. It also will be understood that the base or first fibers 15 can include technical fibers and the second or additional type of fibers 115 can include staple fibers.

When high performance fibers, such as aramids, para-aramids, meta-aramid fibers, Opan, polyethylene, PBI, PBO, P84® modacrylics, and/or other high performance fibers, are used as the second fibers 115 and are combined with base fibers 15 such as cotton, wool or rayon, the high performance fibers 115 can provide a structural skeleton or base as well as other technical properties such as abrasion and fine resistance, etc. . . . , to increase the performance of fabrics formed from the resultant blended yarns, while the staple fibers 15 may provide comfort and fashion.

For example, technical T-shirts made from a composite yarn 120 including fibers of cotton (as a first type of fibers) and aramids (as the second or additional type) will be lightweight and comfortable to wear with flexibility, moisture wicking, and breathability as desired, and be fashionable in appearance due to the comfort and dyeing characteristics of cotton, but may also have abrasion and heat resistance performance properties due to the presence of aramids splashed in with cotton/modacrylic blend.

In another example, fabrics made from a composite yarn 120 including fibers of 100% Fire resistant Rayon (as the first type) and Opan (as the second or additional type) may result in a T-shirt or other garments which is extremely comfortable to wear and the rayon is easy to dye, thus providing a fashionable appearance (due to presence of rayon), and also has great heat resistance (due to Opan). For example, when fibers of Opan are alternated with fibers of FR Rayon, the Opan fibers can act as a fire break and help prevent propagation of fire into the fabric and greatly reduce the heat shrinkage of the fabric.

Referring again to FIG. 1A, the fibers of the first type 15 are fed to the drafting zone 16 of the spinning frame 20 by operation of the first set of drafting rollers 18, which can be operated at a first speed, which can be a relatively constant speed. At selected intervals, the feeding of the first type or base fibers 15 will be stopped, and feeding of the fibers of one or more additional types 115 (i.e., technical fibers) from their one or more additional rovings 112 will be substantially immediately started to feed or introduce such fibers into the front drafting zone 17, such that there is a substantially continuous flow of fibers into and through the drafting zone. In addition, the front drafting zone 17 can utilize negative pressure to help guide and pull the fibers into the front drafting zone in a compact spinning operation to help ensure a substantially continuous flow of fibers as the feeding of fibers is alternated between rovings. The feeding of the first type or base fibers 15 and the second or additional, technical fibers 115 will be continued in an alternating fashion by control of the first and second sets of drafting rollers 118. The base and technical fibers 15/115 will be alternatingly spun to form a substantially non-homogeneous composite yarn 120, wherein intermingling or blending of the fibers of the first type 15 with the fibers 115 of the additional type is substantially minimized or limited to the junction or points of intersection resulting from alternating the feeding between rovings.

During the spinning process, the base fibers 15 are overlapped with the fibers 115 of the one or more additional types in the spinning frame to form the substantially non-homogeneous blend 120, with the first fibers 15 being alternately and substantially overlapped with the second fibers 115 by alternating the introduction of the fibers of the drafting zone 16 of the spinning frame 20. As a result, successively the first fibers 15 and second fibers 115 are successively attached and detached in the spinning frame 20. For example, the fibers may be drafted from rovings 12 and 112 without an effective drafting break, whereby as the first fibers 15 fed from the first roving 12 is stopped, the feeding/drafting of the second fibers 115 from the second roving 112 is started substantially immediately to prevent a break in the resultant blended yarn 120. By minimizing or avoiding a lag between when the first fibers 15 from the first roving 12 is stopped and the second fibers 115 from the second roving is started, the points of intersection where the fibers from the different rovings are blended are minimized so that the resultant composite yarn 120 will be spun as a substantially smooth yarn without weakness in the transitions between the fibers. The resultant composite yarn 120 thus will have/maintain a high yarn break strength at the transitions between rovings with consistent weights per linear length, while also incorporating selected splashes or bands of color from the technical fibers therealong.

In addition, while the process above indicates a single stop and start operation, wherein the introduction of the base fibers 15 from the first roving 12 is stopped while the introduction of the second fibers 115 from the second roving is substantially immediately started, in other embodiments, this process may be repeated in a cycle until a resultant composite yarn 120 of a substantially non-homogeneous blend of the first fibers 15 and the second fibers 115 is obtained. Also, by alternating between rovings of different fibers or fiber blends, a fabric formed from the blended yarn 120 can be inherently made of different colors, and can be provided with unique fashionable fabric features/attributes, as well as having the ability to be dyed, printed or otherwise colored with various different colors or shades, thereby providing a more casual or leisurely looking performance garment.

In an embodiment, the fibers 15 of the first type are overlapped with the fibers 115 of the second type by a length less than about 10 cm. In another embodiment, the fibers 15 of the first type 10 generally overlapped with the fibers 115 of the second type by a length less than 1-4 cm. In such an embodiment, the yarn break strength of the blended yarn 120 during overlapping is greater than about 60%-75% of a mean yarn break strength of the blended yarn 120. The resultant composite yarn 120 further generally is provided with substantially the same weight per linear length throughout the yarn and minimizes weak spots in yarn construction. By managing the timing of switching or overlapping of the fibers 15 of the first type with the fibers 115 of the at least one other type, small splashes of different material can be intermingled, thus forming yarns of increased performance capabilities as well as with unique color blends.

The speed of the different sets of drafting rollers 18/118, and the timing of when feeding of the fibers of the first type 15 is started or stopped and for how long, and the timing of when feeding of the fibers of the one or more additional types 115 is started or stopped and for how long, depends on the performance characteristics, comfort levels and color requirements of the fabric formed from the resultant composite yarn 120. Typically, the duration of feeding of fibers from any one roving will be determined based upon a duration sufficient to feed a length of the selected fiber (e.g., the technical or performance fibers) that will provide the level of technical performance properties and appearance to the finished composite yarn. The fiber lengths of each of the base and technical fibers chosen preferably are of about the same fiber length but can vary somewhat. In various embodiments, percentage ranges of such fibers can incorporate up to about 100% of a single type of a particular performance fiber, such as 100% para-aramid or Opan fibers, with differing percentages being selected for desired appearance and performance attributes, and as low as about 2%-5%; for example, for a blend of anti-static fibers for static dissipation introduced into a fiber bundle of other technical or natural fibers such as modacrylic, wool, cotton or combinations thereof.

The speed and timing of the drafting rollers and the changeover process is preferable controlled by a control system or controller having programming to monitor and effect the changeover between rovings once the prescribed lengths of fibers have been fed. This allows for a rapid changeover and variable speeds to achieve different levels of performance and color characteristics. For example, allowing longer lengths of first type 15 of fibers through the drafting rollers and then rapidly switching from the first type 15 of fibers to the second type 115 of fibers results in small splashes of the fibers of the second type 115 to be non-homogeneously blended in the resultant composite yarn 120, providing optical enhancement as well as increased strength of a fabric formed from the blended yarn 120.

FIG. 2 is a flowchart illustrating a method 200 of making a composite yarn 120 per FIG. 1. The method 200 includes introducing fibers of a first type 15 from a first roving 12 to a first set of drafting rollers 18 of a spinning frame (step 210). The method 200 further includes alternately introducing fibers of one or more additional types 115 from one or more additional rovings 112 to one or more additional sets of drafting rollers 118 of the spinning frame (step 220). The fibers of the first type 15 and the fibers of one or more additional types 115 may include complementary characteristics, such as the comfort and softness provided by the fibers of the first type 15 may be complemented by the fire or heat resistance provided by the fibers of the at least one other type 115. The method 200 further includes a step 230 of braking the feeding of the fibers of the first type 15, and as the feeding of the fibers of the first type is stopped, substantially immediately starting feeding of the fibers of the one or more additional types 115 from the additional roving(s). The feeding of the different type fibers will be selectively alternated between the rovings. For example, by varying the length and/or the time of feeding of the additional, technical fibers into the spinning frame with the fibers of the first type 15 overlapping with the fibers of the one or more additional types 115 by successively attaching and detaching the fibers of the first type 15 and the fibers of the one or more additional types 115 at discrete intervals of generally less than about 10 cm, and in some embodiments, less than about 1-4 cm. The resultant composite yarn 120 will incorporate the technical or performance fibers together with the staple fibers in amounts sufficient to provide selected splashes or bands/lengths of colors (e.g. black, yellow, red) and desired structural strength and other technical properties such as heat/fire/flame resistance, cut and/or abrasion resistance, and/or static dissipation with the comfort, softness, flexibility, moisture wicking and/or other attributes of the staple or base fibers.

In addition, performance fabrics can be made from the composite yarn 120 of FIGS. 1A-1B that can be used in forming lightweight protective apparel, shade or awning materials, and other articles having enhanced heat and/or cut protection as well as enhanced comfort and moisture-wicking characteristics, but which also have a fashionable, aesthetically pleasing appearance. Such fabrics may be made of woven or knitted construction, but also could be formed by other methods, including braiding, tufting, etc. FIGS. 3A-3C illustrate examples of fabrics made from the blended yarn 120 that are woven in a fashionable or aesthetically appealing pattern (i.e., a plain pattern, a twill pattern, a basket pattern, a satin pattern, a leno pattern, a crepe pattern, a dobby pattern, a herringbone pattern, a Jacquard pattern, a pique pattern, a warp pile, or in a weave configuration), and which incorporate splashes, bands or shadings of colors such as black or red due to the inclusion of the technical or performance fibers, which further provide enhanced strength and structural support to the fabric as well as additional technical/performance attributes or properties such as cut and/or abrasion resistance, heat and/or fire/flame resistance, and/or static dissipation properties. In another embodiment, such a fabric may be knitted to form articles of clothing, such as a jersey, a rib, a purl, a fleece, a double weft, a tricot, a raschel, a warp knit or a flat knit construction.

The fabrics formed from the blended yarns 120 can be used to form various performance and/or protective garments. For example, such fabrics can be used to form underlayment type garments for fire fighters, military, arc flash protection and other users, including T-shirts or other, similar garments that are comfortable to wear, lightweight and flexible to enable substantially full freedom of movement, with inherent performance characteristics such as an increased strength and abrasion resistance and resistance to heat shrinkage and burning when exposed to flames, while also having a fashionable appearance so that the T-shirts etc. . . . can be worn for more general, everyday use. Still further, such fashionable, aesthetically pleasing performance fabrics can be used in other applications such as for umbrellas, awnings and other shade type fabrics, and for blankets and/or other articles where comfort and fashion are preferred, but for which increased strength, cut and abrasion resistance, heat and/or flame resistance and other performance properties are also desired or required.

Although only a few exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the embodiments of the present disclosure. Accordingly, all such modifications are intended to be included within the scope of the embodiments of the present disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

Claims

1. A method of forming a composite yarn, comprising:

Introducing a series of fibers of a first type from a first roving to a first set of drafting rollers of a spinning frame, the first type of fibers comprising a series of staple fibers;

spinning the fibers of the first type at the spinning frame;

alternately stopping feeding of the fibers of the first type and introducing one or more additional types of fibers selected as having one or more technical properties including at least one of cut resistance, abrasion resistance, heat resistance, fire resistance, static dissipation, and/or increased strength, from at one or more additional rovings to the spinning frame;

spinning and integrating the fibers of the one or more additional types of fibers with the fibers of the first type, wherein feeding of the fibers of the first type is alternated with feeding of the fibers of the one or more additional types of fibers such that the fibers of the first type and the fibers of the one or more additional types of fibers are successively attached and detached at minimized points of intersection to form a composite yarn having discrete lengths of the one or more additional fibers interspersed with the fibers of the first type to provide structural support and incorporate technical properties and bands of color of the one or more additional fibers with additional attributes of the first fibers to form the composite yarn with the technical properties of the selected additional types of fibers and aesthetic features integrated therein.

2. The method of claim 1, whereby spinning and integrating the fibers of the first type and the one or more additional types of fibers further comprises overlapping the fibers of the first type with the fibers of the one or more additional types by less than about 4 cm.

3. The method of claim 1, whereby spinning and integrating the fibers of the first type and the one or more additional types of fibers further comprises overlapping the fibers of the first type with the fibers of the one or more additional types by less than about 10 cm.

4. The method of claim 3, wherein a yarn break strength of the composite yarn at the points of intersection between the fibers of the first type and the fibers of the one or more additional types is greater than approximately 60% of a mean yarn break strength measured along a length of the composite yarn.

5. The method of claim 1, wherein a speed of the first set of drafting rollers and a speed of the one or more additional sets of drafting rollers are variable.

6. The method of claim 1, wherein the fibers of the first type and the fibers of one or more additional types comprise fibers including a material selected from a group comprising: para-aramids, Meta-aramids, modacrylics, oxidized polyacrylonitrile, high density polyethylene (HDPE), Vectran™, polyphenylene sulfide (PPS), kynol, polybenzimidazole (PBI), polybenzoxazole (PBO), fire resistant nylon, fire resistant polyester, polyvinyl alcohol (PVA), fire resistant rayon, cotton, wool, polyester, acrylic, nylon, and blends thereof.

7. The method of claim 1, wherein the fibers of the first type comprise cotton, wool, or rayon; and wherein the fibers of the one or more additional types comprise aramids, para-aramids, meta-aramids, modacrylics, oxidized polyacrylonitrile, high density polyethylene, Vectran™, polyphenylene sulfide (PPS), kynol, polybenzimidazole (PBI), polybenzoxazole (PBO), fire resistant nylon, fire resistant polyester, polyvinyl alcohol (PVA), fire resistant rayon, polyester, acrylic, nylon 6/6.6 and Fr nylon, polyimide fibers, and blends thereof.

8. The method of claim 1, further comprising weaving or knitting the composite yarn to form a fabric having a substantially non-homogeneous appearance.

9. The method of claim 8, wherein the composite yarn is knitted to form a fabric selected from a group comprising: jersey, rib, purl, fleece, doubt weft, tricot, raschel, warp knit, and combinations thereof.

10. The method of claim 8, wherein the blended yarn is woven to form a fabric including a pattern selected from a group comprising: plain, twill, basket, satin, leno, crepe, dobby, herringbone, Jacquard, pique, warp pile, weave, and combinations thereof.

11. The method of claim 1, wherein the aesthetic features of the composite yarn comprise color attributes incorporating colors from alternating and integrating the fibers of the first type with the fibers of the one or more additional types.

12. A lightweight performance fabric, comprising a series of composite yarns formed by spinning staple fibers selected to provide attributes including at least on of comfort, flexibility, softness, and/or dyeability and fed from a first roving with a series of technical fibers selected as having one or more technical properties including at least one of cut resistance, abrasion resistance, heat resistance, fire resistance, static dissipation, and/or increased strength and fed from a second roving, wherein the feeding of the staple fibers is selectively alternated with the feeding of the technical fibers so as to overlap the staple fibers and the technical fibers at points of intersection between the staple fibers and the technical fibers by less than 10 cm during spinning so as to successively attach and detach the fibers of the first type and the technical fibers to form a spun composite yarn with a substantially non-homogeneous, fashionable appearance incorporating colors and selected technical or protective properties of the technical fibers with the attributes of the staple fibers.

13. The fabric of claim 12, wherein the fibers of the first type are overlapped with the fibers of the one or more additional types by less than 4 cm, and wherein a yarn break strength of the composite yarn at the overlap is greater than approximately 60% of a mean yarn break strength of the blended yarn.

14. The fabric of claim 12, wherein the fibers of the first type overlap with the technical fibers by less than 1 cm, and wherein the yarn break strength of the blended yarn at overlap is greater than approximately 70% of the mean yarn break strength of the blended yarn.

15. The fabric of claim 12, wherein the fibers of the first type comprise staple fibers that are dyeable, printable and the fibers of the one or more additional types comprise fibers of a second material that is not easily dyed.

16. The fabric of claim 12, wherein the fabric and the yarn display streaks of colors obtained by alternating and integrating the fibers of the first type with the fibers of the one or more additional types.

17. The fabric of claim 12, the staple fibers comprise cotton, wool, or rayon; and

wherein the technical fibers comprise aramids, para-aramids, meta-aramids, modacrylics, oxidized polyacrylonitrile, high density polyethylene, Vectran™, polyphenylene sulfide (PPS), kynol, polybenzimidazole (PBI), polybenzoxazole (PBO), fire resistant nylon, fire resistant polyester, polyvinyl alcohol (PVA), fire resistant rayon, polyester, acrylic, nylon 6/6.6 and Fr nylon, polyimide fibers, and blends thereof.