Wool like yarn for carpets and the like
AssigneeAYM Syntex Limited
InventorAbhishek Rajesh MANDAWEWALA
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Abstract
A method of manufacturing a wool-like yarn from continuous filaments of polymer material comprises steps of: providing partially oriented, continuous filaments of the polymer; drawing and air texturizing the partially oriented filaments to form threads, wherein a first group of straight filaments forms a core of the thread and a second group of filaments are overfed with respect to the first group of filaments to form a hairy sheath; and twisting or cabling a plurality of the threads together to form the wool-like yarn to have a weight of greater than 2000 dtex. The resulting wool-like continuous filament yarn is intrinsically UV resistant, antistatic and recyclable.
Claims28
A method of manufacturing a wool-like yarn from continuous filaments of polymer material, wherein the yarn is obtained by a process comprising steps of:
- providing at least partially oriented, continuous filaments of the polymer;
- drawing and air texturizing the filaments to form threads, wherein a first group of straight filaments forms a core of the thread and a second group of filaments are overfed with respect to the first group of filaments to form a hairy sheath;
- twisting and/or cabling a plurality of threads together to form the wool-like yarn having a weight of greater than 2000 dtex.
The method of any one of the preceding claims, wherein the partially oriented, continuous filaments are of a multilobal cross-sectional shape.
The method of any one of the preceding claims, wherein the partially oriented, continuous filaments are provided as a plurality of multi-filament tows, preferably provided with nips to hold each tow together.
The method of any one of the preceding claims, wherein drawing and air texturizing takes place simultaneously in a continuous process.
The method of any one of the preceding claims, wherein drawing is performed at a temperature in a range of 130° C.-200° C.
The method of any one of the preceding claims, wherein the second group of filaments are overfed with respect to the first group of filaments by between 30% and 150%, preferably around 80%.
The method of any one of the preceding claims, wherein a dtex weight ratio of the filaments in the core to the filaments in the sheath is between 1:1 and 1:6, preferably 1:2.
The method of any one of the preceding claims, wherein the thread has a dtex in a range of from 500 dtex to 5000 dtex, preferably 2000 dtex to 3000 dtex.
The method of any one of the preceding claims, wherein from 2 to 20 threads are twisted and/or cabled together to form the wool-like yarn.
The method of any one of the preceding claims, wherein the yarn is twisted in a range of from 30-400 twists per meter (TPM).
The method of any one of the preceding claims further comprising heat setting of the twisted yarn to maintain the twist at a temperature below the drawing temperature, preferably in a temperature range between 85° C.-110° C.
The method of any one of the preceding claims, wherein the polymer is selected from the group consisting of polyesters, polyamides, polypropylene and copolymers thereof, preferably polyester.
A wool-like yarn for the manufacture of floor coverings, the yarn comprising continuous filaments of polymer material, assembled together to form threads with first straight filaments forming a core of the thread and second textured filaments forming a hairy sheath around the core and wherein a plurality of threads are twisted or cabled together to form a heavyweight yarn of greater than 2000 dtex.
Dependencies are inferred from the claim text.