EP-4735678-A1 - DYED YARN RETAINING ELONGATION PROPERTIES

Abstract

A dyed yarn having a staple fiber core yarn and a bicomponent filament yarn in an outer sheath surrounding the staple fiber core yarn is described. The bicomponent filament includes two polymers having different shrinking properties during dyeing process. An undyed yarn is wound on a perforated tube in a controlled way so that a tension of the undyed yarn wound on the perforated tube is varying. A percent elongation of the dyed yarn is proximate to a percent elongation of the undyed yarn. The percent elongation of the dyed yarn being between 20 – 30 %. A fabric made using the dyed yarn is also described.

Inventors

• MANNA, Rovin
• DANDAPURE, YOGENDRA V.
• JACKSON, Aaron Rae

Assignees

• Lululemon Athletica Canada Inc.

Dates

Publication Date

20260506

Application Date

20240610

Claims (20)

1. 1. A dyed yarn having: a staple fiber core yam; and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process; wherein an undyed yam is wound on a perforated tube in a controlled way so that a tension of the undyed yam wound on the perforated tube is varying; and wherein a percent elongation of the dyed yam is proximate to a percent elongation of the undyed yam, the percent elongation of the dyed yam being between 20 - 30 %.
2. 2. The dyed yam of claim 1 , wherein the undyed yam wound on the perforated tube has a first tension value on an inside of the perforated tube and has a second tension value in an outside of the perforated tube, the first tension value being different than the second tension value, a difference between the first tension value and the second tension value allowing retention of percent elongation of the dyed yam.
3. 3. The dyed yam of claim 2, wherein the first tension value is greater than the second tension value.
4. 4. The dyed yam of claim 3, wherein the tension of the undyed yam on the perforated tube gradually decreases from the first tension value toward the second tension value.
5. 5. The dyed yam of claim 3, wherein the undyed yam wound on the perforated tube has a third tension value in a middle of the perforated tube.
6. 6. The dyed yarn of claim 1 , wherein the bicomponent filament yam in the outer sheath comprises a synthetic filament.
7. 7. The dyed yam of claim 6, wherein the synthetic bicomponent filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof.
8. 8. The dyed yam of claim 6, wherein the synthetic bicomponent filament is polyethylene terephthalate (PET) and polyethylene (PE), polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET) and nylon, polytrimethylene terephthalate (PTT) and nylon, or polyethylene (PE) and nylon.
9. 9. The dyed yam of claim 1 , wherein the staple fiber core yam comprises a natural staple yam.
10. 10. The dyed yam of claim 9, wherein the staple fiber core yam is made of a material that includes cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and/or any blend combination thereof.
11. 11 . The dyed yam of claim 10, wherein the staple fiber core yam is made of a micro modal.
12. 12. The dyed yam of claim 9, wherein the staple fiber core yam further comprises a synthetic filament or staple.
13. 13. The dyed yam of claim 1 , wherein the bicomponent filament yam in an outer sheath comprises two filaments of bicomponent filament yam spun around the staple core yam.
14. 14. A fabric comprising: a face side comprising a first yam, the first yam comprising a first dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process, wherein a first undyed yam is wound on a perforated tube in a controlled way so that a tension of the first undyed yam winded on the perforated tube is varying, and wherein a percent elongation of the first dyed yam is proximate to a percent elongation of the first undyed yam, the percent elongation of the first dyed yam being between 20 - 30 %; and a back side comprising a second yam, the second yam comprising a second dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process, wherein a second undyed yam is wound on a perforated tube in a controlled way so that a tension of the second undyed yam winded on the perforated tube is varying, and wherein a percent elongation of the second dyed yam is proximate to a percent elongation of the second undyed yam, the percent elongation of the first dyed yam being between 20 - 30 %.
15. 15. The fabric of claim 14, wherein the fabric is knitted.
16. 16. The fabric of claim 15, further comprising a connecting yam connecting the face side and the back side.
17. 17. The fabric of claim 16, wherein the connecting yam comprises an elastane material.
18. 18. The fabric of claim 17, wherein the connecting yam is a filament of elastane.
19. 19. The fabric of claim 15, wherein the fabric is double jersey knitted fabric, single jersey knitted fabric, tricot knitted fabric, interlock knitted fabric.
20. 20. The fabric of claim 14, wherein at least one of the face side and the back side are brushed.

Description

DYED YARN RETAINING ELONGATION PROPERTIES BACKGROUND [0001] The present embodiments relate to a dyed yam that retains its elongation properties, a method of preparing a dyed yam to retain elongation properties, and fabric articles made using the dyed yam. [0002] Combination yams incorporating bicomponent filaments can have different shrinking percentages during the dyeing process that cause damage to the dyed yam. As a result, the elongation properties of the dyed yam are reduced compared to the elongation properties of the combination yam prior to dyeing. [0003] There exists a need in the art for a dyed yam that retains its elongation properties after the dyeing process and fabric articles, including sportwear and other garments, made using such yams. SUMMARY [0004] In one aspect, the disclosure provides a dyed yam having a staple fiber core yam, and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam. The bicomponent filament includes two polymers having different shrinking properties during dyeing process. An undyed yam is wound on a perforated tube in a controlled way so that a tension of the undyed yam wound on the perforated tube is varying. A percent elongation of the dyed yam is proximate to a percent elongation of the undyed yam. The percent elongation of the dyed yam being between 20 - 30 %. [0005] In another aspect, the disclosure provides a fabric having a face side including a first yam. The first yam including a first dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam. The bicomponent filament including two polymers having different shrinking properties during dyeing process. A a first undyed yam is wound on a perforated tube in a controlled way so that a tension of the first undyed yam winded on the perforated tube is varying. A percent elongation of the first dyed yam is proximate to a percent elongation of the first undyed yam. The percent elongation of the first dyed yam being between 20 - 30 %. The fabric also having a back side including a second yam. The second yam including a second dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam. The bicomponent filament including two polymers having different shrinking properties during dyeing process. A second undyed yam is wound on a perforated tube in a controlled way so that a tension of the second undyed yam winded on the perforated tube is varying. A percent elongation of the second dyed yam is proximate to a percent elongation of the second undyed yam. The percent elongation of the first dyed yam being between 20 - 30 %. [0006] In another aspect, the disclosure provides a method of preparing an undyed combination yam for a dyeing process. The method includes winding the undyed combination yam around a tube of a spool at a first tension until the undyed combination yam reaches a first thickness at a first boundary. The method further includes continuing to wind the undyed combination yarn around the tube of the spool over the first thickness of the undyed combination yam at a second tension until the undyed combination yam reaches a second thickness at a second boundary. The method also includes continuing to wind the undyed combination yam around the tube of the spool over the first thickness and the second thickness of the undyed combination yam at a third tension until the undyed combination yam reaches a third thickness at a third boundary. [0007] Other systems, methods, features and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims. BRIEF DESCRIPTION OF THE DRAWINGS [0008] The disclosure can be better understood with reference to the following drawings and description. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. Sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes and sizes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. [0009] FIG. 1 is a representative view of an example embodiment of a combination yam including a core yam surrounded by a bi-component filament yam; [0010] FIG. 2A is a schematic view of an example embodiment of forming a combination yam with a bi-component filament yam surrounding the core yam; [0011] FIG. 2B a schematic view of an example embodiment of forming a