IES79041B2 - Improvements in and relating to the manufacture of yarns and products of tufted fabrics therefrom - Google Patents

Abstract

The invention provides a man-made yarn formed from at least two separate cables twisted and set together. Each cable is formed from a bundle of eg. polymide filaments twisted and preset together. The filaments of one cable may have a fineness of say 5 denier and those of the other 15 denier so that the individual cables contract differently in the dyeing process of a tufted mat to cause the yarn to "twist and curl down". This combined with the differences in reflection and refraction caused by the different fineness of the individual filaments and the different fineness possibly of the individual cables causes the finished rug to have a unique appearance.

Description

Improvements in and relating to the manufacture of yarns and production of tufted fabrics therefrom Introduction The present invention relates to yarns and in particular to yarns of man-made fibres. One of the particular uses for such yarns is in tufted fabrics as in the manufacture of mats, rugs and carpets, wall hangings, upholstery and other articles, hereinafter mats.

Such man-made fibres are often a polyamide material such as sold under the generic name NYLON which is used to describe any manufactured fibre in which fibre-forming substances are any long chain synthetic polyamide having recurring polyamide groups (-CONH-) as an integral part of the polymer chain. These can be formed from various combinations of diacids, diamines or amino acids and they may also be formed by additional polymerization. These linear polyamides have achieved great commercial success and are particularly used in the manufacture of rugs and carpets. Many other synthetic fibres or polymers are used extensively and are manufactured in many ways. The yarns formed from these materials generally comprise one or more bundles of filaments extruded from a number of nozzles which are cut into bundles which in turn are then often wound around each other to form a cable and then as groups of cables are twisted to form a composite yarn. For example a typical yarn would be one formed from two separate cables spun together each of 1200 denier, each of which would in turn be formed from a number of spun filaments each of substantially the same denier + 1 denier and then usually of 4 to 25 denier.

D / 7 Ο · - 2 When fabrics are made from such yarn and are dyed, the general affect is of a composite material which does not show any variation in colour.

In this specification the term bundle is used to refer 5 to the filaments as extruded, cable for the bundles which have been twisted and possibly partially heat set or preset together and then yarn as being a number of cables twisted and possibly set together depending on the process used according to the invention. Thus, one has filaments in bundles, in turn forming cables and in turn forming a composite yarn.

In general individual filaments, cables and yarns are measured by their fineness. The fineness is in general a reasonably accurate measurement of their thickness and general construction. However, the definition of fineness used for these man-made fibres is, strictly speaking, not a unit of thickness but a weight for a specific length of filament, cable or yarn. The general unit of fineness used in the trade is the denier which is equal to the fineness of a yarn weighing 0.05g for each 450m of length or lg for each 9000m of length. One will often see the term denier used to actually denote fineness of a filament or a yarn. This it will be appreciated is strictly speaking incorrect as it is the unit of measurement of fineness which is the best measure of the relative constructions of differing filaments or yarns.

The present invention is directed towards providing an improved construction of yarn and in particular an improved construction of yarn that would be more aesthetically pleasing when tufted into a mat, dyed and subsequently tumble dried. In particular the invention is directed towards providing an improved tufted mat.

Statements of Invention According to the invention there is provided a yarn comprising at least two separate cables twisted together in which each cable comprises a bundle of spun filaments, the individual filaments of each cable having substantially the same fineness, and in which the individual filaments of one cable have a substantially different fineness from those of another cable.

The cables maybe heat set together and the spun filaments may be twisted together and further the filaments may be heat preset together. Additionally, the fineness of one cable is substantially different to the fineness of another cable and ideally the ratio of fineness of individual filaments is in the ratio 4:1 and may be in the ratio 2:1. In one particular embodiment of the invention the fineness of the filaments are under 10 denier and the fineness of the thickest filaments is between 10 and 25 denier. Ideally, the fineness of the cables vary in the ratio 3:1 but may be in the ratio 2:1. Generally the denier of the fineness cable is under 1500 denier and the fineness of the thickest cable is between 1500 and 3000 denier.

The major advantage of the yarn according to the present invention is when it is tufted into a mat dyed and tumble and there will be a variation in colour between the various cables because the individual filaments making up the cables will have different fineness. Thus, when twisted and set together the finer filaments will contract more and do not take up as much colour as the heavier filaments during the subsequent dyeing and tumble drying. Further, the yarn will bend and twist because the individual cables and filaments are set together and cannot move independently. It has been found that this provides a more natural fluffy appearance where the yarn seems to twist and curl down on itself which refracts and reflects the light in varying degrees of intensity giving a more aesthetically pleasing appearance in certain uses such as for example, on the surface of a mat. There are two factors leading to this effect namely the filament or cable colour variation and the twist and curl down effect which lead to a clearly distinctive look on the surface of a mat quite different to anything commercially available.

Detailed Description of the Invention A yarn according to the present invention is essentially manufactured in the same way as any other yarn of synthetic spun materials such as any man-made fibre. However, the yarn is made up of at least two separate cables and each cable comprises a bundle of spun filaments twisted and preset together, the individual filaments of each cable having substantially the same fineness. This is exactly the same as the way in which a conventional yarn is made. For example in accordance with the invention when two cables make up the yarn the fineness of individual cables making up the one cable may be substantially the same, the fineness of the filaments of the first cable will differ significantly from the fineness of the filaments of the second cable. More than one cable may be used and ideally when more than one cable is used then the fineness of the individual filaments in each of the cables is different to that of the other cables .

When in this specification the term substantially different fineness is used, what is meant is that the fineness difference between the two cables must be such that, when dyed, colour taken up will appear to be different to the naked eye than that of the colour of another filament. The whole purpose is to ensure that the fineness of the filaments are chosen as to ensure 'a different colour take-up on dying. It has been found that ideally the ratio of fineness of individual filaments should be of the order of 4:1 and may be of the order of 2:1 which ensures adequate change in colour. It should, however, be noted that depending on the colour being dyed, the ratio of fineness may be changed. It has been found that ideally the finest filaments should be under 10 denier and the thickest between 10 and 20 denier.

It has also been found to be advantageous to have the fineness of the individual cables different and, indeed, it has been found that a ratio of 3:1 or even 2:1 can be desirable. Then it has been found that the denier of the finest cable is under 1500 denier and the thickest between 1500 and 3000. The yarn may be provided by many cables and, indeed, some of the cables may have, not alone filaments of substantially the same fineness but may themselves be of substantially the same fineness. What we have found is that by departing from the conventional way of manufacturing such yarn it is possible to produce yarns which have a more aesthetically pleasing look to them when made into certain fabrics and in particular into tufted fabrics for rugs, mats and carpets. Various cloths and fabrics have been produced for garments and for other articles which have again provided an aesthetically pleasing look substantially similar to that provided by more natural fabrics.

It is envisaged that in any one cable there may be filaments of substantially different fineness but in general this will not be necessary.

It has been found with plain and tufted fabrics manufactured from yarns according to the invention that after repeated washing the fabric does not become dead as is the case with conventionally manufactured fabrics.

The yarn may fade, however, the individual cables fade at different rates so that there is still a colour contrast within the individual yarns and thus the fabric has a lively look to it. For example, when manufacturing a tufted fabric yarn according to the present invention the yarn may be manufactured in the normal way and the tufted mat produced. The tufted mat is then dyed and subsequently tumble dried to caused the dyed yarn in the mat to twist and curl giving a lively appearance to the mat. This produces a unique appearance of mat.

Modifications of the invention will be made within the scope of the claims without departing therefrom.

Claims (5)

1. A yarn comprising at least two separate cables twisted and preferably heat set together in which each cable comprises a bundle of spun filaments twisted and preferably heat preset together, the individual filaments of each cable having substantially the same fineness, and in which the individual filaments of one cable have a substantially different fineness from those of another cable in which the fineness of one cable is substantially different to the fineness of another cable .

2. A yarn as claimed in claim 1 in which the ratio of fineness of individual filaments is in the ratio of 5:1 or preferably 2:1 and the finest filaments are under 10 denier, and the fineness of the thickest filaments is between 10 and 20 denier.

3. A yarn as claimed in claim 1 or 2 in which the fineness of the cables vary in the ratio 4:1 or preferably 2:1, and in which the denier of the finest cable is under 1500 denier, and the fineness of the thickest cable is between 1500 and 3000 denier.

4. A yarn substantially as hereinbefore described with reference the examples.

5. A mat manufactured from a tufted fabric as claimed in any preceding claim.