[go: up one dir, main page]

WO2025129268A1 - Fil pour tissu et tissu - Google Patents

Fil pour tissu et tissu Download PDF

Info

Publication number
WO2025129268A1
WO2025129268A1 PCT/AU2024/051396 AU2024051396W WO2025129268A1 WO 2025129268 A1 WO2025129268 A1 WO 2025129268A1 AU 2024051396 W AU2024051396 W AU 2024051396W WO 2025129268 A1 WO2025129268 A1 WO 2025129268A1
Authority
WO
WIPO (PCT)
Prior art keywords
yarn
fabric
approximately
multifilament yarn
denier
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/AU2024/051396
Other languages
English (en)
Inventor
Andrew Nasarczyk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gale Pacific Ltd
Original Assignee
Gale Pacific Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2023904176A external-priority patent/AU2023904176A0/en
Application filed by Gale Pacific Ltd filed Critical Gale Pacific Ltd
Publication of WO2025129268A1 publication Critical patent/WO2025129268A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/04—Pigments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D01F1/106—Radiation shielding agents, e.g. absorbing, reflecting agents
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/06—Patterned fabrics or articles
    • D04B21/08—Patterned fabrics or articles characterised by thread material
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/02—Moisture-responsive characteristics
    • D10B2401/021—Moisture-responsive characteristics hydrophobic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/22—Physical properties protective against sunlight or UV radiation
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/18—Outdoor fabrics, e.g. tents, tarpaulins

Definitions

  • the invention relates to a yarn and a fabric formed from the yarn, specifically, a yarn and a fabric suitable for use both indoors and outdoors, the fabric having a use as a component of furniture and fixtures such as blinds, cushions, canopies and shade cloth, as well apparel, shoes, and other general textile applications
  • Blended canvases are made from a combination of cotton and synthetic yarns, which allow for enhanced durability and water resistance, thus making blended canvases an ideal and suitable fabric for outdoor furniture and fixtures, and for use in apparel often worn or applied outdoors.
  • Synthetic yarns and resulting fabrics have been further developed to enhance performance, in particular, resistance to UV degradation, durability, and heat absorption and dissipation. These, amongst others, are essential considerations manufacturers make in the development of yarns for outdoor fabrics and furniture.
  • the amount of heat absorbed can be unbearable, for example, on a clear summer day.
  • the fabric of a tent, a chair, a mat, a hat, or a marquee will absorbs a great amount of radiant heat on a clear summer day, making the fabric unbearable to touch and uncomfortable to use.
  • the fabric often becomes hotter than its surrounding environment, resulting in heat transfer to the surrounding environment through conduction and/or convection.
  • Mitigating heat absorption is an important consideration when designing fabrics which are exposed to sunlight.
  • One such measure employed to mitigate heat absorption is to provide apertures throughout the fabric to facilitate ventilation, which has limited effectiveness.
  • Another measure includes the use of reflective coatings which can be expensive, harmful to the environment, and which often degrade over time.
  • the fabric manufacturing industry is aware of disposal and recyclability issues.
  • the industry is averse to entirely redesigning the yarn and fabric makeup for a few reasons, some of which include preserving performance existing characteristics, or the manufacturing and optimisation of machinery tailored for specific fabric and yarn makeups.
  • improvements to ingredients used in the manufacturing of fabrics have been made to reduce the environmental impact a fabric has, particularly once disposed.
  • environmentally harmful additives such as toxic inks and pigments have been replaced with inks and pigments that are not toxic.
  • Another innovation has been to use a water-based coating which is biodegradable. Once disposed in landfill the water-based coating does not contaminate the soil or any adjacent water streams.
  • the present invention seeks to provide a versatile yarn which enhances in-use comfort, is strong enough to withstand a variety of stresses and conditions, and which can be aesthetically tailored.
  • a multifilament yarn for use in the composition of a fabric to be incorporated into furniture and fittings, the yarn comprising: a polypropylene content of at least approximately 80%, a denier of at least approximately 100D, a tenacity of at least approximately 2 grams per denier (g/d),
  • UltraViolet (UV) additive content of approximately 0.0-1.0%, an IR reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0% all of which are incorporated in the yarn during the yarn extrusion process; and wherein the yarn is solution dyed during a yarn extrusion manufacturing process.
  • the yarn can be woven or knitted to form a fabric which can be used in a variety of furniture, fittings, fixtures, apparel or other textile applications.
  • the yarn tenacity provides the yarn and the subsequently knitted or woven fabric sufficient strength with stand stress and force the fabric may be subjected to, for example, at a range above 2 g/d, a fabric made of the yarn of the present invention can support the mass of a person or an object when used in the form a suspension chair or a suspension table, or any other piece of furniture or fitting required to support mass. Additionally, its tenacity gives it sufficient strength to withstand external elements when in the form of an umbrella canopy, or any item to remain predominantly outdoors, or under consistent mechanical stress.
  • the yarn is versatile and can be used to form a woven or knitted fabric with a wide variety of end uses both indoor and outdoor.
  • the denier and tenacity of the yarn not only contribute to a fabric's properties, but they allow the yarn to be used in a knitting or weaving manufacturing process without issue.
  • the specified tenacity of at least 2grams per denier and a net denier of approximately at least 100D allows the yarn to have adequate strength whilst also maintaining a level of flexibility to ensure its versatility during manufacturing, and its end use as fabric.
  • the inclusion of the combination of an ultraviolet additive, an IR pigment, a dispersive additive, and an IR reflective additive allows for the yarn to be used on tactile surfaces without absorbing heat.
  • the yarn's heat reflective properties serve to increase comfort and reduce the wear and tear of the yarn, thus prolonging its life while providing a comfortable surrounding environment.
  • the UV additive is comprised of Hindered Amines Light Stabilsers (HALS).
  • HALS Hindered Amines Light Stabilsers
  • the yarn is solution dyed during the fibre manufacturing process, there is no risk of colour run-off or paint degradation. Rather, being solution dyed, the yarn has enhanced colour preservation in comparison to surface dyed yarns which are prone to fading, degradation, peeling and run-off. In this respect, the colour is 'locked-in' to the polymer matrix.
  • the yarn is predominantly made up of polypropylene, thus reducing the complexity around the recycling of a fabric made predominantly of the yarn, either knitted or woven. Being predominantly polypropylene, complex polymer separation techniques are not required to recycle the yarn/fabric. Further, as the yarn is solution dyed as opposed to surface dyed, there is no risk of toxic dye run off. This not only simplifies the recycling process, but also makes the yarn safer to use in a domestic environment, and desirable for applications with direct skin contact.
  • a fabric made of the yarn of the present invention can be entirely recycled at a relatively low cost.
  • the yarn being solution dyed, and capable of being either knitted or woven gives it the yarn both a function and aesthetic versatility, making it suitable for plethora of fabric manufacturing techniques and end uses/products.
  • the yarn is predominantly made of polypropylene, it is possible that it contains trace amounts of other polymers to enhance its strength. The small amounts of other polymer/s may not necessarily alter the simplified recycling process; however, it may result in a lower quality recycled material.
  • the yarn may be polypropylene homopolymer so as to ensure a relatively higher quality recyclate.
  • the yarn denier is between approximately 100D and 1000D.
  • the yarn denier can be chosen depending on the end use of the fabric into which it will be woven or knitted into to. In a preferred embodiment, the yarn denier is between 400D and 600D. [0024] In an embodiment, the yarn comprises approximately 72 to 288 fibers per filament, and preferably approximately 144 fibers per filament. The number of filaments per fibers can be adjusted to create a yarn with a specific denier. Alternatively, the denier of each individual filament/fiber can be adjusted, or both can be adjusted. In this respect, in an embodiment the denier of each filament of the yarn may be approximately 1.0D and up to at least 8.0D.
  • the weight of the yarn is an important factor, particularly when the yarn is used to form a fabric for use in applications where weight is important, for example, a portable marquee or umbrella cover, a blind or clothing.
  • the fabric comprises a weight of approximately 100 to 600 grams per square metre (GSM).
  • the yarn may in an embodiment incorporate an antimicrobial additive.
  • Antimicrobial additives such as MicrobanTM are comprised of silver ion, or zinc oxide, composites which are inherently antimicrobial. This serves to slow or entirely stop mould and mildew from growing or forming on the yarn.
  • the antimicrobial additive may be applied post extrusion, however, for longevity it is incorporated into the yarn during the extrusion manufacturing process.
  • the yarn may be comprised of up to 0.5% by wt antimicrobial additive.
  • the yarn may also comprise a hydrophobic surface treatment.
  • the treatment may be applied after the extrusion process, however, to allow for the hydrophobic properties to be long lasting, the treatment may be incorporated during the extrusion manufacturing process.
  • the surface treatment may be any one of a TeflonTM finish, or a silicone solution, or zinc oxide nanoparticles. Given the polypropylene's inherent hydrophobicity the total hydrophobic surface treatment content can be relatively modest so as to not adversely affect other material properties.
  • the content of the surface treatment additive is approximately 0.5% to approximately 2% and preferably approximately 1% by wt.
  • the aesthetic of the yarn can be manipulated to make it appear like a natural fibre.
  • the yarn may be texturised.
  • the yarn texturization process is a dedicated process which occurs after the yarn has been extruded. Texturising techniques can include bulking (where thermoplastic yarns are twisted, heat set and untwisted), crimping and coiling, amongst others.
  • the yarn of the invention in any one or a combination of the above embodiments may be used to form a fabric through traditional textile conversion processes including, but not limited to, weaving, warp knitting, and tricot knitting
  • a knitted fabric for shading applications comprised partially or entirely of the multifilament yarn as described in the preceding paragraphs.
  • the yarn of the knitted fabric comprises a denier of approximately 450D, a dpf of approximately 3.1.
  • the fabric is comprised of a 12-gauge knit pattern and a weight of 310 gsm, wherein the UV block of the fabric is between approximately 90 to 100%.
  • This fabric may be manufactured on a compound or latch needle warp knitting machine having two guide bars being a first (GB1), and a second (GB2), guide bar, wherein the guide bars follow the following knit pattern to manufacture the fabric:
  • Such a fabric may be used as an umbrella or a shade cloth or a marquee cover and have a UV block of approximately 90 to 100%.
  • the knitted fabric is comprised partially or entirely of a multifilament yarn having a denier of approximately 800 to 1000D, a dpf of approximately 6.6, a tenacity of at least 6.0g/D.
  • the fabric is comprised of a 6- gauge knit pattern and a weight of 340 gsm, wherein the UV block of the fabric is at least 80%.
  • the fabric may be manufactured on a compound or latch needle warp knitting machine having four guide bars being a first (GB1), a second (GB2), a third (GB3), and a fourth (GB4) guide bar wherein the guide bars follow the following knit pattern to manufacture the fabric:
  • GB4 may run a monofilament High Density Polyethylene (HDPE) or Polypropylene (PP) yarn of approximately 600D.
  • the HDPE yarn is used to provide the fabric with enhanced properties such as strength and stiffness.
  • the fabric may be a suspension fabric in which a degree of flexibility is required to allow for comfort and durability, particularly where the suspension fabric is to be a suspension seat and back cover/wrap.
  • the UV block may be relatively lower to that of an umbrella and may be at approximately at least 80%.
  • a woven fabric comprised of the multifilament yarn according to any form or embodiment of the invention as previously discussed.
  • the multifilament yarn comprises a denier of approximately 600 D, and a dpf of approximately 4.2.
  • the fabric is comprised of a weave pattern of 19x15 yarns/cm and a weight of 220 gsm, wherein the UV block of the fabric is approximately at least 98%.
  • Such a fabric may be suitable as a cushion cover of an outdoor couch. However, given the density of the weave pattern, the fabric may be significantly less breathable than a knitted fabric. However, it is envisaged that the heat reflective properties of the yarn make this fabric superior to existing woven cushion covers for outdoor couches.
  • the multifilament yarn comprises a denier of approximately 150 D, and a dpf of approximately 3.2.
  • the fabric can be knitted to any desirable pattern, with a weight range from 50 to 500gsm.
  • Such a fabric may be suitable as an outer layer for a shoe, or other general textile applications
  • the yarn of the present invention exhibits relatively lower infrared wavelength absorption, and thus limits the build-up of heat/temperature after exposure to sunlight or similar light sources when compared to conventional fibres and fabrics. This provides and higher level of comfort as well as prolonging the life of the yarn. Further, being predominantly polypropylene, the relatively heat resistant yarn can be recycled with relative ease, and without the need for complex polymer separation.
  • polypropylene as the main ingredient allows for ease of fabrication, high abrasion resistance, tear and fray resistant, and enhanced durability and resilience allowing the yarn and resulting fabric to have some stretch.
  • the yarn of the present invention is not susceptible to runoff/leeching of colour or surface coating as all colours and hydrophobic coatings, and antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process.
  • antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process.
  • the present invention is directed to not only the incorporation and combination of these additives into a yarn, but to the actual quantity of each additive, the quantity ranges along with yarn dimensions and any corresponding ranges, which in combination yield a versatile and relatively environmentally friendly yarn suitable for forming a fabric for use in indoor and outdoor settings.
  • Polyproplylene yarn has been broadly referenced in this Summary of Invention, alternate polymeric materials can also be applicable.
  • Replacement synthetic fibres such as, but not limited to, Polyethylene Terephthalate (PET or Polyester), Polyamide (Nylon) or PolyAcrylonitrile (Acrylic), can also be applicable to this invention.
  • the present invention relates to a yarn and a fabric comprised partially or entirely of the yarn.
  • the yarn is predominantly comprised of polypropylene.
  • the properties of the yarn are such that any woven or knitted fabric comprising the yarn can be used in a variety of settings across a variety of products such as an outdoor umbrella, an outdoor or indoor cushion cover, an outdoor or indoor couch cover, a pet bed, a chair cover, a suspension chair seating surface, a storage bag, a carry bag, a sports bag, a privacy screen, a shade cloth, a marquee cover, a picnic or beach blanket, clothing, shoes or any other conceivable product or fixture.
  • the yarn properties such as denier, tenacity, polypropylene content, weave or knit pattern, and additive content can be tailored for a particular use or purpose.
  • the yarn requirements for an umbrella differ to the yarn requirements for a clothing, shoe or suspension chair.
  • additives and pigments there are limitations to the inclusion of additives and pigments.
  • Inclusion of additives into the extrusion manufacturing process reduces the total polypropylene content in the extruded yarn. A reduction in polypropylene content can adversely affect the strength and performance properties of the yarn, however, the inclusion of the additives improves other performance aspects of the yarn such as heat resistance, hydrophobicity, and antimicrobial properties.
  • the yarn of the present invention has been formulated to account for different uses and for the inclusion of additives in the extrusion manufacturing process.
  • the formulation has been carefully developed to provide a yarn that is capable of being used in a manufacturing process without breaking, and to also provide a versatile yarn that can be used to form fabrics for a wide range of uses without significantly compromising the innate properties of polypropylene.
  • the yarn is a multifilament yarn formed by an extrusion manufacturing process. While the yarn can be a monofilament and formed by other means, the inventors found a multifilament yarn extruded yarn to be easier to mass manufacture and one that performs at a higher standard.
  • the multifilament yarn is comprised of at least approximately 80% by wt polypropylene with an overall denier of at least approximately 100D.
  • the high polypropylene content gives the yarn properties unique to polypropylene. These properties include flexibility, durability, chemical resistance, and light weight.
  • the yarn is a polypropylene homopolymer. This significantly simplifies the recycling process of the yarn, or a fabric made entirely of the yarn, as complex polymer separation is not required. In alternative embodiments it is possible for the yarn to include other polymers in the yarn makeup.
  • the denier of the yarn can be increased to cater to different purposes as will be discussed in the proceeding paragraphs, and it is to be appreciated that a minimum denier of approximately 100D is required to develop a yarn that performs to a minimum standard for fabric manufacture.
  • the yarn is comprised of a minimum tenacity of approximately 2 grams per denier (g/d) to withstand stresses during a weave or knit manufacturing process, whilst also satisfying minimum strength requirements of a fabric for both indoor, outdoor and personal use.
  • the yarn can be comprised of an UltraViolet (UV) additive content of approximately 0.0-1.0%, an IR reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0%.
  • UV UltraViolet
  • IR reflective pigment content approximately 0.5-4.0%
  • dispersive additive content approximately 0.0 to 0.8%
  • IR reflective additive content approximately 0.0 to 1.0%.
  • the alternative to incorporating the additives into the yarn polymer matrix during the extrusion manufacturing process is to coat the extruded yarn with additive and pigment layers which may impart a degree of heat reflectivity. While a heat reflective coating may be initially effective, such a coating has a limited useful life before degrading. The degradation of a coating may result in noxious or toxic run-off if the coating is comprised of noxious or toxic chemicals. Additionally, the recoating process is costly, and it is often more cost effective to replace an entire fabric instead of recoating it.
  • the heat reflective recipe of additives and pigments of the present invention are not expected to leach out or diminish in performance over time.
  • the inclusion of infrared reflective pigments and/or additives in the polymer matrix of the yarn allow for the sector of IR wavelengths that carry heat to be reflected when the yarns are exposed to sunlight, or an equivalent light source, thus reducing the surface temperature of the yarn/fabric.
  • the UV additive in combination with the IR reflective pigment, the dispersive additive and the IR reflective additive reduce the heat absorption of the yarn.
  • the yarn of the present invention In comparison to a yarn that does not have this combination of pigments and additives incorporated into its polymer matrix, the yarn of the present invention remains cooler to touch and emits less radiant/convective heat making it cooler to be around.
  • the benefits of this combination are set out in PCT/AU2023/050477 the contents of which are incorporated herein by this reference.
  • the fabric comprising a similar recipe of additives and pigments to that disclosed in the present application remains approximately 20% cooler than a fabric without heat resistant properties when exposed to sun light over a six hour period.
  • the UV additive incorporated in the yarn can be any suitable additive.
  • the UV additive is Hindered amines light stabilizers (HALS).
  • HALS Hindered amines light stabilizers
  • any one or a combination of the following IR reflective pigments and additives can be used: ColanyalTM Oxide Yellow BV531 and Titanium Dioxide, blended with additional pigments to create a Beige fabric colour.
  • the IR reflective pigment used in the yarn makeup is not restricted to ColanyalTM Oxide Yellow BV531.
  • the IR reflective pigment can be altered to provide a different yarn colour.
  • ColanylTM Scarlet GO532 and/or ColanylTM Oxide Red G531 are used to give the yarn a red colour; and ColanylTM Oxide Blue is used to give the yarn a blue colour.
  • ColanylTM additives are proprietary additives and colours developed by Clariant AG which is owned by Heubach GmbH. These IR reflective pigments can be mixed and matched to obtain a desired colour.
  • a combination of IR reflective pigments is used to obtain a desired colour.
  • any other suitable IR reflective pigment may be used, for example, titanium dioxide, mica, and silicon dioxide all have a pigmentation effect, and may be used alone or in combination with each other and the ColanylTM pigments to obtain a desirable colour. It is to be appreciated that the list of IR reflective pigments is not exhaustive. Other branded IR reflective pigments, or other IR reflective pigments not listed may be used.
  • the IR reflective additive used may be any one of titanium dioxide, or mica, or silicon dioxide, or a combination thereof. It is to be appreciated that additives such as titanium dioxide, mica, and silicon dioxide have a pigmentation effect. As a result, in certain embodiments, the IR reflective additives are used in place of the IR reflective pigments noted above, or in combination with those IR reflective pigments, or in combination with any other suitable IR reflective pigment or additive. It is to be appreciated that the list of IR reflective additives is not exhaustive. Other branded IR reflective additives not listed may be used.
  • the yarn of the present invention is solution dyed during the extrusion manufacturing process. Like the heat resistant ingredients noted in the previous paragraphs, the solution dye is locked into the yarn polymer matrix, thus eliminating any colour leeching or run-off. In this respect, the yarn has improved colour fastness in comparison to a surface dyed or coated yarn, and the colour of the yarn of the present invention is expected to last longer than that of a surface coated yarn.
  • a UV stabiliser can be incorporated into the yarn, and may form part of the heat resistant additives and pigments, and/or the solution or dye, or may be a separate component added during the manufacturing process. The UV stabiliser protects the yarn from long-term degradation due to UV light exposure, where required
  • the heat resistant properties of the yarn of the present invention allow it to be used in fabrics which are to be exposed to sun light and subject to human or animal touch.
  • the heat resistant properties give such fabrics a relatively lower surface temperature (compared to fabrics without the same properties), making them relatively cooler touch, enhancing the users experience.
  • Such fabrics are often found in apparel, shoes, on tables, sofas, chairs, tents, surface rugs, and may be desirable for use on steering wheels, tools, and clothing.
  • the denier can be increased from approximately 100D up to approximately 1000D.
  • the desirable yarn denier is between approximately 400D to 600D.
  • Such a denier is sufficiently large to give a knitted fabric strength to withstand forces generated from wind and rain, whilst also allowing for a knit pattern and density to provide sufficient UV blocking and water repellence properties (depending on the fabric application).
  • the denier range is between approximately 500D and 800D. This denier range is optimal for polypropylene as it results in the formation of an aesthetically pleasing knitted or woven fabric at a cost-effective density while also providing a high UV block rating.
  • the yarn is to be used to form a knitted fabric for a suspension chair back and/or a suspension chair seat, the fabric has enhanced strength and resilience, and a polypropylene yarn having a higher denier range of approximately 800D to 1000D is used.
  • Yarn of this denier is subjected to a coarse knitting process to produce a fabric that can withstand the mass and compressive forces it will be subjected to through chair use by humans and animals.
  • the denier range is between approximately 100D and 300D. This denier range is optimal for polypropylene as it results in the formation of pliable and breathable knitted or woven fabric
  • the yarn can comprise approximately 72 to 288 fibers per filament (fbf) with a denier of each filament (dpf) being at least approximately 1.0D and up to at least approximately 8.0D.
  • Yarn prototypes have been manufactured at 144 fbf, with a maximum denier of approximately 7.0D dpf.
  • the weight of the yarn is an important consideration, particularly where a fabric made of the yarn is to form a structural component of furniture or a fixture, or if the fabric is to be supported by structural components such as umbrella arms, or if the fabric is to be used in an apparel application.
  • the weight of the fabric is dictated by several factors such as the material of the yarn (generally polypropylene in this case), the denier and the fibers per filament.
  • the extruded yarn is tailored to produce fabrics that have a weight within the range of approximately 100 and up to 600 grams per square metre (gsm).
  • the fabric can have a weight above or below this range, it was found that a weight within this range provided was capable of forming a fabric(woven, or knitted or other) that could cater to a wide range of requirements whilst also being versatile enough to have a variety of uses such as shade cloth, blind, clothing, furniture fabric, or a protective synthetic blanket.
  • the yarn of the present invention can incorporate antimicrobial properties in its polymer matrix. This is achieved through the inclusion of an antimicrobial additive during the yarn extrusion process.
  • the weight content of the antimicrobial additive can vary between approximately 0.1% and 1.0% wt of the yarn, depending on the required antimicrobial resistance.
  • Antimicrobial properties are desirable in most outdoor fabrics, in particular those exposed to humidity, water, or human and animal touch.
  • One such example is a pet bed or pet mat where antimicrobial properties are desirable to help ensure the health and safety of pets who are prone to licking a wide range of surfaces and refuse.
  • antimicrobial additives comprise silver ion, or zinc oxide, composites, and in the yarn of the present invention the antimicrobial additive that is included is known as MicrobanTM. Other brands and formulations may be used in place of MicrobanTM. Such additives are known to provide a degree of odour control while resisting the growth of microorganisms like bacteria, mould, and mildew.
  • the yarn of the present application incorporates a hydrophobic surface treatment in its polymer matrix, whereby the surface treatment is incorporated during the extrusion manufacturing process.
  • the surface treatment can be any number of solutions or finishes such as TeflonTM, or a silicon solution, or any suitable solution that enhances hydrophobicity.
  • the yarn is configured to have a hydrophobic surface treatment content of approximately between 0.5% wt and up to 2.0% wt. A content of 1.0% wt was found to provide sufficient hydrophobicity and stain resistance for a fabric made predominantly of the yarn of the present invention.
  • a synthetic yarn has a distinct look compared to a natural yarn.
  • a synthetic yarn can be manipulated to have a certain aesthetic and/or texture.
  • the yarn of the present invention can undergo a texturization process after it has been extruded.
  • texturization processes include 'false twisting', 'direct texturing', 'air jet texturing', 'twisting', and 'box stuffing'.
  • Any one or number of texturization processes can be used to texturise the yarn of the present invention, and in one preferred form air jet texturing is used. This involves texturing a yarn by applying a stream of air that entangles some of the filaments in the flat yarn. Air jet yarn texturing gives a synthetic yarn a similar texture to a conventionally spun yarn, particularly with respect to the yarn's hairiness, and does not provide any strength to the yarn.
  • the yarn has inherent moisture wicking capabilities.
  • Polypropylene has moisture wicking properties and unlike other polymers such as polyester, polypropylene can dry quickly. This makes the yarn of the present invention ideal for forming fabrics that will involve regular and prolonged human contact such as clothing, shoes, chair/cushion fabrics, beach blankets, and picnic blankets.
  • Moisture wicking properties of a fabric are not just dictated by the yarn material, the configuration of the yarn within a fabric is important. Moisture wicking properties of a fabric depend on two primary factors being capillary pressure and permeability. Capillary pressure is the force responsible for the movement of moisture as it is pulled away from a person's skin through. This is caused by the force of surface tension between the liquid and the walls of a narrow gap or pore within the fabric and/or yarn. This overcomes the forces between the molecules in the liquid so that moisture moves into empty gaps until the force evens out.
  • Permeability is a measurement of a fabric's ability to transport moisture through itself, and is determined by gap/aperture sizes within the fabric, which are dictated by yarn denier, weave/knit patterns and density. Fabrics with a higher density/weight (typically due to a smalleryarn denier), tend to comprise a tighter knit/weave and have smaller gaps through which liquids can move through. Factors influencing permeability include the yarn twist, the contact angle between fabric and a liquid, the knit and weave pattern and density, and the texture of the yarn (surface roughness). In this respect, there is a balance to be achieved between UV block and moisture wicking capabilities.
  • the yarn of the present invention is quite versatile and can be used to form a fabric for use in a wide range of applications.
  • the yarn of the present invention is used to form a knitted fabric for an umbrella canopy.
  • the fabric is entirely comprised of the yarn of the present invention.
  • the yarn of the knitted fabric comprises a denier of approximately 450D, a dpf of approximately 3.1.
  • the fabric is formed through a 12-gauge knit pattern and has a weight of 310 gsm.
  • the knit pattern and yarn denier provide a fabric UV block of between approximately 90 to 100%.
  • the fabric is manufactured on a compound or latch needle warp knitting machine having two guide bars being a first (GB1), and a second (GB2), guide bar. The guide bars follow the following knit pattern to manufacture the fabric:
  • the yarn of the fabric is solution dyed, and is comprised of heat reflective ingredients, antimicrobial additives (MicrobanTM), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance, as set out in the preceding paragraphs.
  • the fabric is entirely Per- and polyfluoroalkyl substances (PFAS) free. This allows the fabric to be recycled with relative ease as no complex polymer separation is required to isolate the different polymers.
  • PFAS Per- and polyfluoroalkyl substances
  • the hydrophobic surface treatment may be a TeflonTM finish which would introduce trace amounts of PFAS. It is envisaged that the fabric will be recyclable with the inclusion of PFAS without polymer separation, however, the quality of recyclate may differ to that of a fabric without a PFAS additive.
  • the yarn of the present invention is used to form a woven fabric for use as a cushion cover.
  • the woven fabric is comprised entirely of the multifilament yarn of the invention, the yarn having a denier of approximately 600D, a dpf of approximately 4.2.
  • the fabric is comprised of a weave pattern of 19x15 yarns/cm and a weight of 225 gsm. This arrangement provides a UV block of approximately at least 98%, with a comparatively low breathability compared to the knitted fabric of the first example.
  • the yarn of the fabric is solution dyed and is comprised of heat reflective ingredients as described in the preceding paragraphs.
  • the heat reflective capabilities of the fabric make it relatively more comfortable to sit on, to touch and to be around.
  • the yarn of the fabric also includes antimicrobial additives (MicrobanTM), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance, both of which have been described in preceding paragraphs.
  • the enhanced hydrophobicity of the yarn reduces the moisture wicking capabilities of the fabric.
  • the yarn of the fabric is also texturised to give the fabric a matte aesthetic.
  • this cover fabric is PFAS free.
  • the fabric is entirely recyclable with relative ease as no complex polymer separation is required to isolate the polypropylene.
  • the hydrophobic surface treatment may be a TeflonTM finish which would introduce trace amounts of PFAS. It is envisaged that the fabric will be recyclable with the inclusion of PFAS without polymer separation, however, the quality of recyclate may differ to that of a fabric without a PFAS additive.
  • the yarn of the present invention is used to form a knitted fabric for use as a suspension surface in a suspension chair.
  • the woven knitted fabric is comprised of the multifilament yarn according to the invention.
  • the yarn has a denier of approximately 800-1000D, a dpf of approximately 6.6, a tenacity of at least 6.0g/D.
  • the fabric is comprised of a 6-gauge knit pattern and a weight of 340 gsm.
  • the relatively larger yarn denier provides the fabric with enhanced strength; however, the fabric is more porous to facilitate breathability.
  • the UV block of the fabric is at least 80%, which is lower than that of the knitted and woven fabric examples discussed in the preceding paragraphs.
  • the fabric is manufactured on a compound or latch needle warp knitting machine having four guide bars being a first (GB1), a second (GB2), a third (GB3), and a fourth (GB4) guide bar wherein the guide bars follow the following knit pattern to manufacture the fabric:
  • the fabric in an embodiment includes a yarn that is different to that of the present invention.
  • GB4 may run a monofilament High-density polyethylene (HDPE) or Polypropylene (PP) yarn of approximately 600D.
  • the HDPE yarn is used to provide the fabric with enhanced properties such as stiffness and strength.
  • the fabric is made entirely of the yarn of the present invention.
  • the yarn of the fabric is solution dyed and is comprised of heat reflective ingredients as described in the preceding paragraphs. This makes the fabric relatively comfortable to sit on, to touch and to be around.
  • the yarn of the fabric also includes antimicrobial additives (MicrobanTM), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance.
  • MicrobanTM antimicrobial additives
  • the relatively porous structure of the yarn provides the fabric with enhanced hydrophobicity and moisture wicking capabilities.
  • the yarn of the fabric is also texturised to give the fabric a matte aesthetic.
  • the fabric having a silicon based hydrophobic solution does not have any PFAS.
  • the hydrophobic surface treatment may be a TeflonTM finish which would introduce trace amounts of PFAS.
  • the combination of a HDPE yarn in addition to the polypropylene yarn of the invention increases the recyclability difficulty of the fabric. Separation of the HDPE and the polypropylene polymers will be required. In embodiments where the fabric is made entirely of the yarn of the present invention, the fabric is entirely recyclable with relative ease, and will merely require shredding and pelletisation. Washing is optional and depends on the condition of the fabric.
  • the yarn of the present invention is used to form a tricot knitted fabric comprised of the multifilament yarn according to any form or embodiment of the invention as previously discussed.
  • the multifilament yarn comprises a denier of approximately 150 D, and a dpf of approximately 3.2.
  • the fabric can be knitted to any desirable pattern, with a weight range from 50 to 500gsm. Such a fabric may be suitable as an outer layer for a shoe.
  • the yarn of the present invention exhibits relatively lower infrared wavelength absorption, and thus limits the build-up of heat/temperature after exposure to the sun light or similar light sources when compared to conventional polypropylene yarns.
  • the relatively heat resistant yarn can be recycled with relative ease, and without the need for complex polymer separation.
  • the use of polypropylene as the main ingredient allows for ease of fabrication, high abrasion resistance, tear and fray resistant, and enhanced durability and resilience allowing the yarn and resulting fabric to have some stretch.
  • the yarn of the present invention is not susceptible to runoff/leeching of colour or surface coating as all colours and hydrophobic coatings, and antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process.
  • antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process.
  • the present invention is directed to not only the incorporation and combination of these additives into a yarn, but to the actual quantity of each additive, the quantity ranges along with yarn dimensions and any corresponding ranges, which in combination yield a versatile and relatively environmentally friendly yarn suitable for forming a fabric for use in indoor and outdoor settings.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Artificial Filaments (AREA)

Abstract

Les fils synthétiques existants sont sensibles à des niveaux élevés d'absorption de chaleur. Il est souhaitable de remédier à cela en composant un fil destiné à être utilisé dans un tissu qui a un niveau inférieur d'absorption de chaleur et avec un impact environnemental relativement plus faible. L'invention concerne un fil multifilament destiné à être utilisé dans la composition d'un tissu à incorporer dans un meuble, un pare-soleil, une protection et des accessoires, un vêtement, des chaussures ou d'autres applications textiles générales, le fil comprenant une teneur en polymère d'au moins environ 80%, une ténacité d'au moins environ 2 grammes par denier (g/d), une teneur en additif contre les ultraviolets (UV) d'environ 0,0 à 1,0 %, une teneur en pigment réfléchissant les infrarouges (IR) d'environ 0,5 à 4,0 %, une teneur en additif dispersif d'environ 0,0 à 0,8 %, et une teneur en additif réfléchissant les IR d'environ 0,0 à 1,0 %, tous étant incorporés dans le fil pendant le processus d'extrusion de fil ; et le fil étant teinté en solution pendant un processus de fabrication par extrusion de fil. L'invention concerne également un tissu constitué dudit fil. Ledit fil et ledit tissu ont des propriétés d'absorption de chaleur plus faibles et sont plus respectueux de l'environnement par rapport aux fils existants couramment utilisés.
PCT/AU2024/051396 2023-12-21 2024-12-20 Fil pour tissu et tissu Pending WO2025129268A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
AU2023904176A AU2023904176A0 (en) 2023-12-21 Yarn for fabric and fabric
AU2023904176 2023-12-21
AU2024903768 2024-11-15
AU2024903768A AU2024903768A0 (en) 2024-11-15 Yarn for fabric and fabric

Publications (1)

Publication Number Publication Date
WO2025129268A1 true WO2025129268A1 (fr) 2025-06-26

Family

ID=96136041

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2024/051396 Pending WO2025129268A1 (fr) 2023-12-21 2024-12-20 Fil pour tissu et tissu

Country Status (1)

Country Link
WO (1) WO2025129268A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998050610A1 (fr) * 1997-05-01 1998-11-12 Basf Corporation Fibres de nylon teintes dans la masse
US20170073859A1 (en) * 2015-09-16 2017-03-16 International Textile Group, Inc. Outdoor Cover Product with Stretch Properties
KR20220047423A (ko) * 2020-10-08 2022-04-18 대한민국(농촌진흥청장) 인삼재배용 백색 직조필름
WO2023230669A1 (fr) * 2022-06-02 2023-12-07 Gale Pacific Limited Fibre pour tissu et tissu

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998050610A1 (fr) * 1997-05-01 1998-11-12 Basf Corporation Fibres de nylon teintes dans la masse
US20170073859A1 (en) * 2015-09-16 2017-03-16 International Textile Group, Inc. Outdoor Cover Product with Stretch Properties
KR20220047423A (ko) * 2020-10-08 2022-04-18 대한민국(농촌진흥청장) 인삼재배용 백색 직조필름
WO2023230669A1 (fr) * 2022-06-02 2023-12-07 Gale Pacific Limited Fibre pour tissu et tissu

Similar Documents

Publication Publication Date Title
KR101261916B1 (ko) 한지복합사의 제조방법과 이에 의해 제조한 한지복합사, 이를 이용한 원단의 제조방법 및 이에 의해 제조한 자동차 내장재
EP2443275B1 (fr) Tissus protégeant contre les uv à base de fibres artificielles de cellulose
JP6106487B2 (ja) 機能性繊維
EP2150649B1 (fr) Textiles en fibres de cellulose contenant des nanolignines, procédé d'application de nanolignines sur des textiles et utilisation de nanolignines dans la production textile
JP6213988B2 (ja) ファブリック調遮熱膜材
IL251426B (en) Synthetic-textile hybrid fabric and means and method for manufacturing same
Defonseka Polymeric coating systems for artificial leather: standard and latest technologies
Mather Synthetic textile fibres: polyolefin, elastomeric and acrylic fibres
WO2025129268A1 (fr) Fil pour tissu et tissu
CA2942207A1 (fr) Produit de couverture exterieure dote de proprietes d'extensibilite
DE60328848D1 (de) Markisenstoff und Verfahren zu seiner Herstellung
KR101040214B1 (ko) 난연성 창가리개용 스크린 원단 및 제조방법
JP2017179632A (ja) 抗菌性撥水布帛、それを用いてなる雨具及び衣服
US20250341029A1 (en) Fibre for fabric and fabric
JP6388471B2 (ja) 保温性布帛
JP5770981B2 (ja) 遮熱性織編物および衣料
Uddin Novel technical textile yarns
CN215856598U (zh) 一种羊驼纤维彩格织物
Kashyap Sustainable fibers and fabrics used in home textiles
KR101375750B1 (ko) 발열성이 우수한 생분해성 침장용 직물
JP2015110847A (ja) 保温性布帛
Hendy et al. Indoor air quality between textiles' treatment and human health
JP2016056464A (ja) 機能性繊維
CN215203801U (zh) 一种耐高日晒麂皮绒面料
JP2015014076A (ja) 機能性繊維糸及びこれを用いてなる織編物

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24905201

Country of ref document: EP

Kind code of ref document: A1

DPE1 Request for preliminary examination filed after expiration of 19th month from priority date (pct application filed from 20040101)