Methods and systems for forming a composite yarn
AssigneePatrick Yarn Mills
InventorsGilbert Patrick, Max Bivens
Life of this patent
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Abstract
A method and system for forming composite yarns having selected performance characteristics including cut resistance and/or fire/heat resistance. The composite yarn will include a core of one or more filaments and a fiber bundle wrapped about the core and integrated with one or more additional filaments that help bind the fibers about the core. An additional filament or other composite yarn can be plied together therewith to form the finished composite yarn. The core filament(s) will be selected from cut and/or fire/heat resistant materials, while the fibers of the fiber bundle and the additional filament(s) wrapped about the core can be selected from natural or synthetic fibers or filaments having additional desired properties.
Claims30
A method of making a composite yarn, comprising:
- spinning at least one core filament with a series of staple fibers;
- introducing a first filament during spinning of the series of staple fibers about the at least one core filament, the series of staple fibers and the first filament combining to form a fibrous bundle, the fibrous bundle wrapped about the at least one core filament to form a base yarn that is spun in a first twist direction, the first filament being applied at approximately the same turns per inch as the series of staple fibers;
- and
- plying at least one additional filament or an additional yarn bundle to the base yarn, and twisting the at least one additional filament in a second twist direction opposite the first twist direction to form the composite yarn.
A composite yarn, comprising:
- a base yarn, comprising a core filament having a fibrous bundle spun or twisted thereabout, wherein the fibrous bundle includes a first filament introduced during spinning of a series of sheath fibers about the core filament such that the first filament and the sheath fibers form an integrated filament and fibrous bundle that is twisted about the core filament sufficient to substantially lock and bind the core filament within the integrated filament and fibrous bundle, and wherein, the first filament being twisted with the sheath fibers about the core filament at approximately the same turns per inch as the sheath fibers to produce the base yarn with a first twist direction;
- and
- at least one additional filament or an additional yarn plied and twisted with the base yarn, wherein the at least one additional filament or additional yarn is twisted in a second twist direction opposite the first twist direction sufficient to substantially minimize torque in the composite yarn.
A method of making a composite yarn, comprising:
- spinning a first core filament with a series of fibers and at least one additional filament introduced during spinning so as to form an integrated filament/fiber sheath about the first core filament to form a first component, wherein the first core filament comprises a material having a hardness at least approximately 7.0 or greater on the Mohs hardness scale and which is substantially bound and locked within the filament/fiber sheath;
- plying the first component with a second component, the second component comprising a yarn or filament;
- and
- spinning the first component with the second component to form a composite yarn with the first component forming a core of the composite yarn having a hardness of at least approximately 7.0 or greater on the Mohs hardness scale and wrapped with the second component.
A composite yarn, comprising:
- a first component comprising a formed of a material having a hardness of at least approximately 7.0 on the Mohs hardness scale, a first sheath of fibers spun about the at least one first core filament and an additional filament introduced during spinning of the first sheath of fibers about the core so as to be twisted about the core sufficient to substantially lock the core within the first sheath of fibers;
- and
- a second component comprising a core and a second sheath of fibers applied about the core;
- and
- wherein the first component is ring spun with the second component to form the composite yarn having the first yarn component as the core of the composite yarn with the second yarn component twisted thereabout.
Dependencies are inferred from the claim text.