CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This Patent Cooperation Treaty patent application claims priority to U.S.

Provisional Patent Application No. 62/886,310, filed August 13, 2019, titled "Composite Yarns," and U.S. Provisional Patent Application No. 63/022,175, filed May 8, 2020, titled "Composite Yarns," the contents of which are incorporated herein by reference in their entirety.

FIELD

[0002] The described embodiments relate generally to composite yarns and textiles and articles including the composite yarns and textiles. More particularly, the present embodiments relate to composite yarns including a cellulose-based filament.

BACKGROUND

[0003] A composite yarn may combine a staple fiber component and a filament component. Some conventional composite yarns include filaments which are synthetic in nature, such as nylon or an elastomer. In one configuration, the staple fiber may form a core of the composite yarn and a conventional synthetic filament may be wrapped around the core. In another configuration, a conventional synthetic filament may form the core of the composite yarn and the staple fiber may form a sheath around the core.

SUMMARY

[0004] The present disclosure provides a composite yarn which combines a cellulose- based filament with an organic and/or a recycled synthetic fiber. As examples, the cellulose- based filament may be wrapped around a staple fiber core of the yarn or may be included in a core of the yarn and at least partially surrounded by a staple fiber sheath. The composite yarns disclosed herein can have a reduced environmental impact as compared to composite yarns including conventional synthetic filaments. For example, cellulose-based filaments and organic fibers can be obtained from renewable natural sources and can be biodegradable. Recycled synthetic fibers can help divert plastic from landfills and oceans and their production can be less energy intensive than production of virgin synthetic fibers.

[0005] In some cases the composite yarn comprises a core including an organic fiber, a recycled synthetic fiber, or a combination thereof and a cellulose-based filament at least partially surrounding the core. The cellulose-based filament or a strand comprising multiple cellulose-based filaments may be wrapped around the core. In other cases, the cellulose based filament and the organic fiber and/or recycled synthetic fiber are twisted together.

The cellulose-based filament may be a regenerated cellulose filament, such as a lyocell filament. The organic fiber and/or the recycled synthetic fiber is typically in staple form. These composite yarns can have higher strength than comparably sized yarns spun solely from the staple fiber(s).

[0006] The organic fiber of the core may be a fiber of plant origin or a fiber of animal origin and is typically in staple form. For example, the organic fiber may be a wool fiber or a cellulose-based fiber. The cellulose-based fiber may include one or more of a regenerated cellulose fiber such as a lyocell staple fiber or a bast fiber such as a hemp staple fiber. The core may include more than one type of organic fiber. For example, the core may include a combination of a wool fiber and a cellulose-based staple fiber or a combination of cellulose- based staple fibers. Further, the core may also include a synthetic fiber, such as a recycled synthetic fiber, alone or in combination with an organic fiber. The recycled synthetic fiber is typically in staple form and may be a recycled polyester fiber, a recycled nylon fiber, or the like.

[0007] In additional cases, the composite yarn comprises a core including at least one cellulose-based filament and a sheath at least partially surrounding the core and including an organic fiber. The cellulose-based filament may be a regenerated cellulose filament, such as a lyocell filament. The organic fiber of the core is typically in staple form. The composite yarns disclosed herein can provide yarns with the appearance and “feel” of the organic fiber but with higher strength than comparably sized yarns spun from the organic staple fiber.

[0008] The organic fiber may be a fiber of plant origin or a fiber of animal origin. For example, the organic fiber may be a wool fiber or a cellulose-based fiber. The sheath may include more than one type of organic fiber. For example, the sheath may include a combination of a wool fiber and a cellulose-based staple fiber. Further, the sheath may predominantly include organic fibers but may also include a synthetic fiber.

[0009] In addition, the composite yarns disclosed herein can be used to make knitted or woven textiles. These textiles can be used in variety of articles including clothing, footwear, and accessory articles. For example, a clothing article may include a textile having a knitted structure, the textile including a composite yarn of the present disclosure. Clothing articles such as shirts, leggings, socks, undergarments, and the like can be produced from the finely knit textiles disclosed herein. These articles may have a reduced environmental impact as compared to conventional articles having a higher synthetic content.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like elements. [0011] FIG. 1 shows an example of composite yarn having a filament wrapped core structure.

[0012] FIG. 2 shows an additional example of a composite yarn having a filament wrapped core structure. [0013] FIG. 3 schematically shows a composite yarn having a core-sheath structure.

[0014] FIG. 4 shows a detail view of a region of the composite yarn of FIG. 3.

[0015] FIG. 5 shows the composite yarn of FIG. 3, with a portion of the yarn cut away to show the core.

[0016] FIG. 6 shows an additional example of a composite yarn having a core-sheath structure.

[0017] FIG. 7 shows an example of a shoe including a composite yarn.

[0018] FIG. 8 shows an example of a pair of leggings including a composite yarn.

[0019] FIG. 9A shows a first example of a sock made, at least partially, from a composite yarn. [0020] FIG. 9B shows a second example of a sock made, at least partially, from a composite yarn.

[0021] The use of cross-hatching or shading in the accompanying figures is generally provided to clarify the boundaries between adjacent elements and also to facilitate legibility of the figures. Accordingly, neither the presence nor the absence of cross-hatching or shading conveys or indicates any preference or requirement for particular materials, material properties, element proportions, element dimensions, commonalities of similarly illustrated elements, or any other characteristic, attribute, or property for any element illustrated in the accompanying figures.

[0022] Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented therebetween, are provided in the accompanying figures merely to facilitate an understanding of the various embodiments described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated embodiment to the exclusion of embodiments described with reference thereto. DETAILED DESCRIPTION

[0023] Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred implementation. To the contrary, the described embodiments are intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the disclosure and as defined by the appended claims.

[0024] The following disclosure relates to composite yarns including at least one cellulose-based filament. The cellulose-based filament may be wrapped around a staple fiber core of the yarn or may be included in a core of the yarn and at least partially surrounded by a staple fiber sheath. Recent advances have allowed production of cellulose- based filaments, such as lyocell filaments, having good mechanical properties. Composite yarns including renewably sourced cellulose-based filaments can have a reduced environmental impact as compared to conventional composite yarns having a staple fiber core wrapped with synthetic filaments or having a core consisting of synthetic filaments.

[0025] In some cases, the composite yarn includes a cellulose-based filament wrapped around a core including an organic fiber, a recycled synthetic fiber, or a combination thereof. The cellulose-based filament may be a regenerated cellulose filament, such as a lyocell filament. The organic fiber and the recycled synthetic fiber may be in staple form. When the core includes an organic fiber, the composite yarn may include at least 40%, 50%, 60%, or 70% and up to about 85% by weight of the organic fiber. In some cases, the composite yarn may include from about 40% to about 60% by weight of the organic fiber. When the core includes a recycled synthetic fiber, the composite yarn may include 30% to 70% or 40% to 60% by weight of the recycled synthetic fiber. In some cases, the core may predominantly include one or more of an organic fiber or a recycled synthetic fiber, but may also include a virgin synthetic fiber. The composite yarn may include from about 15% to about 40% or from about 40% to about 60% of the cellulose-based filament.

[0026] In some examples, the composite yarn includes a core including a wool fiber, a regenerated cellulose staple fiber, a bast fiber, a recycled synthetic fiber, or a combination thereof and a lyocell filament wrapped around the core. When the core includes a fine wool fiber, the fine wool fiber can contribute softness and moisture wicking properties to the composite yarn. A core including a moisture-wicking recycled synthetic fiber such as polyester may also contribute moisture wicking properties to the composite yarn. Bast and regenerated cellulose staple fibers can be renewably sourced are also biodegradable. Therefore yarns including these fibers can have a reduced environmental impact as compared to yarns including fibers which are not renewably sourced and/or biodegradable.

[0027] In additional cases, the composite yarn includes a cellulose-based filament twisted with a strand including an organic fiber, a recycled synthetic fiber, or a combination thereof. When the strand includes an organic fiber, the composite yarn may include at least 40%, 50%, 60%, or 70% and up to about 85% by weight of the organic fiber. In some cases, the strand may include from about 40% to about 60% by weight of the organic fiber. When the strand includes a recycled synthetic fiber, the composite yarn may include 30% to 70% or 40% to 60% by weight of the recycled synthetic fiber. The strand may be a staple fiber strand. In some cases, the staple fiber strand may predominantly include one or more of an organic fiber or a recycled synthetic fiber, but may also include a virgin synthetic fiber. The composite yarn may include from about 15% to about 40% or from about 40% to about 60% of the cellulose-based filament.

[0028] In some examples, the composite yarn includes a lyocell filament twisted with a strand including any of a wool fiber, a bast fiber, a regenerated cellulose staple fiber, a recycled synthetic fiber, or a combination thereof. These composite yarns can have similar benefits to those in which the lyocell filament is wrapped around the core.

[0029] In further cases, a composite yarn has a core-sheath structure and includes at least one cellulose-based filament in the core. The cellulose-based filament may be a regenerated cellulose filament, such as a lyocell filament. The sheath typically includes an organic fiber, such as a wool fiber and/or a cellulose-based fiber. The sheath may also include a synthetic fiber. The filament(s) of the core may provide at least 2% and up to 5%, 10%, or 15% of the yarn while the fibers of the sheath may make up the remainder of the yarn.

[0030] Including an organic fiber in the sheath in combination with the cellulose-based filament of the core can give the composite yarn a high content of renewably sourced materials and a low environmental impact. When the sheath predominantly includes one or more organic fibers, the composite yarns can have the appearance and “feel” of the organic fiber(s) but have a higher strength than a comparably sized yarn spun from the organic fiber(s). For example, when the sheath includes a fine wool fiber, the fine wool fiber can contribute softness and moisture wicking properties to the composite yarn. In some embodiments, the sheath may be wholly formed from organic fibers.

[0031] Textiles knitted or woven from these composite yarns can be incorporated into articles such as clothing, footwear, or accessory articles. Finely knit textiles suitable for activewear and undergarments are also provided by the disclosure herein. [0032] These and other embodiments are discussed below with reference to FIGs. 1 to 9B. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting.

[0033] FIG. 1 shows an example of a composite yarn 100 having a filament wrapped core structure. The composite yarn 100 includes multiple filament fibers 118 wrapped around a core 115 including the fibers 112. The fibers 112 are typically staple fibers. The example of FIG. 1 is not limiting and in some cases, a greater or a lesser number filament fibers may be wrapped around the core 115.

[0034] As shown in FIG. 1 , the filament fibers 118 need not completely cover the core. The yarn 100 may also be described as having a wrapped structure in which the filament fibers 118 and the fibers 112 of the core 115 alternate at the surface of the yarn. Such a structure allows the fibers 112 of the core to contribute to the "feel" of the composite yarn. A composite yarn having a filament wrapped core structure may be produced by a process such as a siro-fil or embeddable and locatable spinning process.

[0035] In some cases, the composite yarn 100 may predominantly include the fibers 112 of the core 115. For example, the fibers of the core may make up at least 50%, 60%, or 70% and up to about 85% by weight of the composite yarn. In additional cases, the fibers of the core may make up from 30% to 70% or 40% to 60% by weight of the composite yarn.

The amount of the filament fibers and the amount of the core fibers together may make up greater than 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even up to 100% by weight of the composite yarn.

[0036] The yarn 100 may be characterized by a yarn number. The metric yarn number (Nm) is a measure of the number of meters per gram of the yarn. In some cases, the metric yarn number is from 25 to 100, from 25 to 75, from 25 to 50 or from 50 to 100 for a single strand. A standard method test method, such as an ASTM test method (e.g., ASTM D1059), may be used to determine the yarn number of the yarns described herein.

[0037] In the example of FIG. 1 , the filament fibers 118 define a filament strand 117. In some cases, the filament fibers 118 in the filament strand 117 may be twisted. When the filament fibers are relatively fine and have a relatively low linear density, the filament strand may include from 10 to 100 filaments. When the filament fibers have a higher linear density the filament strand may include fewer filaments. In some cases, a single filament may be wrapped around the core. One measure of the wrapping of the filament strand 117 around the core 115 is the number of turns per unit distance. In some cases, the number of turns per meter is from 100 turns to 10,000 turns per meter.

[0038] In some cases, each of the filament fibers 118 is a regenerated cellulose-based filament, also referred to herein as a regenerated cellulose filament. Regenerated cellulose fibers and filaments include, but are not limited to, rayon, viscose, and lyocell fibers and filaments. In some embodiments, the regenerated cellulose-based filament is a lyocell filament. Lyocell filaments and fibers are produced using the lyocell process. The lyocell process can have reduced environmental impacts as compared to some other fiber production processes due to its use of renewable source materials, a non-toxic solvent, and a high efficiency of solvent recycling. The lyocell filament may have a strength approaching that of a synthetic filament such as polyester or nylon filament. For example, the lyocell filament may have a tensile strength from 500 MPa to 800 MPa, from 600 MPa to 900 MPa, or from 600 MPa to 700 MPa. The tensile strength of cellulose-based filaments may be determined using standard methods, such as ASTM methods.

[0039] The filament strand 117 may have a linear density from 25 dTex to 175 dTex, from 25 dTex to 160 dTex, from 30 dTex to 75 dTex, or from 50 dTex to 160 dTex. The individual filaments 118, such as lyocell filaments, may have a linear density from 1 dTex to 10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3 dTex, from 5 dTex to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex to 50 dTex. When each filament has a linear density from about 1 dTex to about 5 dTex, the filament strand may include from 25 to 100 filaments. The filament strand may include a fewer number of fibers when each filament has a higher linear density. A standard method test method, such as an ASTM test method or an ISO test method (e.g., ISO 1973:1995), may be used to determine the linear density of the fibers, strands, and yarns described herein.

[0040] In additional cases, the filament strand may include includes one or more synthetic filaments. The synthetic filament may include at least a portion of recycled material. For example, when the synthetic filament is a nylon filament, the nylon fiber may include at least a portion of recycled nylon.

[0041] In some embodiments, the core 115 includes a single type of fiber 112. For example, the core may comprise or consist essentially of an organic fiber or a recycled synthetic fiber. The organic fiber may be of animal origin, such as from sheep, goats, silkworms, and the like. Fibers of animal origin include, but are not limited to, wool, cashmere, and silk fibers. The organic fibers may also be of plant origin, such as from trees (e.g., eucalyptus, beech), bamboo, cotton plants, flax plants, and the like. Fibers of plant origin include, but are not limited to, cellulose-based fibers (also referred to as cellulosic fibers). Cellulose-based fibers include seed fibers such as cotton, bast fibers such as hemp or linen, and regenerated cellulose fibers such as rayon fibers. Regenerated cellulose fibers include, but are not limited to, viscose, modal, and lyocell fibers and can be made from wood pulp and other plant sources such as bamboo and hemp. The recycled synthetic fiber may be a recycled polyester staple fiber, a recycled nylon staple fiber, or the like. In some cases, the fibers 112 may be provided in a staple fiber strand, which may or may not be twisted.

[0042] In some cases, the core 115 includes a wool fiber. Fine wool fibers, such as fibers having a mean or an average diameter less than 24 microns, less than 20 microns or even less than or equal to 17.5 microns, may be used to provide a soft “handle” to the resulting textile. The wool fiber may be a merino wool fiber. A test method established by the International Wool Testing Organization (IWTO) or the American Society for Testing and Materials (ASTM) may be used to determine the average diameter of wool fibers. IWTO standards include IWTO-8-2011 , IWTO-12-2012, and IWTO-47-2013. ASTM standards include D3991 , D6466, and D6500. For example, the wool fiber may make up from 50% to 85%, from 60% to 85%, greater than 65% to 85%, or from 70% to 85% by weight of the composite yarn. The amount of the filament fiber and the amount of the wool fiber together may make up greater than 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even up to 100% by weight of the composite yarn. It is to be understood that reference in the present disclosure and claims to a type of fiber in the singular form (e.g., "a wool fiber") typically includes reference to one or more fibers of that type (e.g., multiple wool fibers).

[0043] In additional cases, the core 115 includes a cellulose-based fiber. The core may include one or more of a regenerated cellulose staple fiber or a bast staple fiber. As examples, the core may include a lyocell staple fiber, a hemp staple fiber, a linen/flax staple fiber, or a combination of these. In some embodiments, the regenerated cellulose staple fiber or a bast staple fiber has a linear density from 1 dTex to 50 dTex, from 2 dTex to 30 dTex, from 2 dTex to 20 dTex, from 1 dTex to 10 dTex, or from 1 dTex to 5 dTex. The staple length may be from 20 mm to 40 mm or from 25 mm to 50 mm.

[0044] In further cases, the core 115 includes a recycled synthetic polymer fiber also referred to herein simply as a recycled synthetic fiber. The recycled synthetic fiber may be a recycled polyester fiber, a recycled nylon fiber, or the like. In some embodiments, the synthetic fiber has a linear density from 1 dTex to 5 dTex. In other embodiments, the synthetic fiber may have a linear density less than or equal to 1dTex, such from 0.1 dTex to 1 dTex, from 0.1 dTex to 0.5 dTex, from 0.1 dTex to 0.3 dTex, or from 0.3 dTex to less than 1 dTex. [0045] The yarn may include from 30% to 70%, 40% to 60%, or greater than 50% to 70% by weight of the synthetic fiber; and from 30% to 70%, 40% to about 60%, or 30% to less than 50% by weight of the filament fiber. The amount of the filament fiber and the amount of the synthetic fiber together may make up greater than 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or even up to 100% by weight of the composite yarn.

[0046] The recycled synthetic fiber includes at least a portion of recycled polymer. In some cases the synthetic fiber includes from 50% to 100%, from 60% to 100%, from 60% to 100%, from 70% to 100%, from 80% to 100%, or from 90% to 100% by weight of the recycled polymer. When the synthetic fiber includes less than 100% by weight of the recycled polymer, the recycled polymer may be blended with virgin polymer. For example, a polyester fiber such as polyethylene terephthalate (PET) may include at least a portion of recycled PET (also referred to as R-PET). When the polyester fiber includes less than 100% by weight R-PET, the R-PET may be blended with virgin PET (also referred to as V-PET). Polymers may be recycled by a physical process involving pellet forming and extrusion. Polymers may also be recycled by a chemical process in which the polymer is decomposed into depolymerized oligomers.

[0047] FIG. 2 shows an additional example of a composite yarn 200 having a filament wrapped core structure. The composite yarn 200 includes multiple filament fibers 218 wrapped around a core 215. In the example of FIG. 2, the core 215 includes a fiber blend 210 which includes two different types of staple fiber, a fiber 212 and a fiber 216. The composite yarn 200 may have a linear density and other physical properties similar to those described for the composite yarn 100 and the filament fibers 218 and the filament strand 217 may have compositions and physical properties similar to those described for the filament fibers 118 and the filament strand 117. For brevity, those details are not repeated here.

[0048] As shown in FIG. 2, the core 215 of the yarn 200 includes a fiber blend 210 including two different types of fibers, a first fiber 212, which is an organic fiber, and a second fiber 216, which is different from the first fiber; the second fiber may also be organic in many embodiments. The first fiber 212 and second fiber 216 may be in staple form.

[0049] For example, the first fiber 212 may include a wool fiber, such as a merino wool fiber. The wool fiber may have similar physical properties to the wool fiber previously described with respect to the core 115 and, for brevity, that description is not repeated here. In some embodiments, the second fiber 216 may be an organic staple fiber different from the first fiber 212. As an example, the second fiber 216 may be a cellulose-based staple fiber such as a lyocell staple fiber. In some embodiments, the cellulose-based fiber has a linear density from 1 dTex to 3 dTex. For example, the amount of the wool fiber may be at least 40%, 50%, 60%, or 70% by weight of the core 215. In some embodiments, the amount of the wool fiber is greater than or equal to the amount of the cellulose-based staple fiber and the composite yarn 200 may predominantly include the wool fiber. The amount of the wool fiber and the amount of the cellulose-based staple fiber together may make up at least 80%, 90%, or 95% by weight of the core 215.

[0050] Alternately, the second fiber 216 may be a synthetic fiber in staple form. For example, the synthetic fiber may include one or more of a nylon fiber, a polyester fiber, an acrylic fiber, and the like. The synthetic fiber may be a recycled polyester fiber, a recycled nylon fiber, and the like or may be a virgin synthetic fiber. The synthetic fiber (recycled or virgin) may have a composition and/or a physical property that is similar to that of the recycled synthetic fiber previously described with respect to the core 115 and, for brevity, that description is not repeated here. For example, the amount of the wool fiber may be at least 40%, 50%, 60%, or 70% by weight of the core 215 and in some cases the amount of the wool fiber may be greater than or equal to the amount of the synthetic fiber. As another example, the amount of the synthetic fiber may be at least 40%, 50%, 60%, or 70% by weight of the core 215. The amount of the wool fiber and the amount of the synthetic fiber together may make up at least 80%, 90%, or 95% by weight of the core 215.

[0051] In additional cases, the first fiber 212 may include a cellulose-based fiber and the second fiber 216 may include a different cellulose-based fiber or a synthetic fiber. For example, the first fiber 212 may be a regenerated cellulose-based fiber, such as a lyocell staple fiber, and the second fiber 216 may be a bast fiber, such as a hemp staple fiber or a linen staple fiber (or vice versa). The cellulose-based fibers may have a composition and/or a physical property that is similar to that of the cellulose-based fibers previously described with respect to the core 115 and, for brevity, that description is not repeated here.

[0052] The example of FIG. 2 shows a core 215 including two different types of fiber. In additional examples, the core may include a blend of more than two types of fiber. For example, the core may include a blend of a wool fiber, a cellulose-based staple fiber, and a synthetic fiber. The amount of the synthetic fiber may be less than that of the wool fiber and the cellulose-based fiber. In a further example, the core may have an interior region including an elastomeric filament, such as a spandex filament, in a similar fashion as described with respect to FIG. 3. For brevity, that description is not repeated here.

[0053] In some embodiments, the yarn may be made of the following fibers: 48% lyocell; 21% wool; 15% nylon (including recycled nylon); 7% polyester (including recycled polyester); and 2% spandex. In other embodiments, the yarn may be made of the following fibers: 47% lyocell; 21% wool, 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 12% polyester (including recycled polyester, such as 6% recycled polyester and 6% unrecycled polyester); and 2% spandex. In still other embodiments, the yarn may be made of the following fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester (including unrecycled polyester, such as 4% recycled polyester and 4% unrecycled polyester); and 2 % spandex. It should be appreciated that the percentages given may be by weight, density, volume, or any other appropriate characteristic (as may any set of percentages discussed herein). Further, although particular percentages have been provided, it should be understood that any or all of the above percentages, with respect to any of the embodiments, may vary by as much as 3% in either direction in absolute terms, or by as much as 20% in relative terms. “Absolute terms” refers to the percentage as a portion of the full makeup of the yarn; thus, if a fiber is given as 21% of a fiber in one example and varies by 3% in absolute terms, it may be as little as 18% or as much as 24% of a yarn in various embodiments. “Relative terms” refers to a percentage of the material making up the yarn; thus, given the same fiber that is 21% of a yarn, it may be as little as 16.8% or as much as 25.2% of the yarn in relative terms (e.g., 80% or 21% or 120% of 21%). Variations in percentages may occur during manufacturing, or may be a result of changing a fiber’s constituent elements to provide different material properties, such as stretch, tensile strength, resistance to damage, breathability, and so on.

[0054] It should be appreciated that the ranges disclosed herein, as well as the combination of various fibers in a yarn, provide unique and unusual benefits for yarns. For example, the use of recycled fibers in yarns (and, in particular, in yarns for clothing, shoes, and the like) in the amounts shown is unusual and difficult to achieve. The percentages and ranges given for the combination of organic fibers (such as wool) and other fibers (such as lyocell, nylon, polyester, spandex, and the like) may result in a recyclable fiber and/or a fiber that is relatively durable, breathable, and/or resistant to wear while not being brittle, shearable, or separable, as opposed to other fiber blends used to form yarns.

[0055] In some cases the composite yarn includes a cellulose-based filament or filament twisted with a strand including an organic fiber, a recycled synthetic fiber, or a combination thereof. The cellulose-based filament or cellulose-based filament strand may have one or more properties which are similar to those of the cellulose-based filament or cellulose-based filament strands described with respect to FIGs. 1 and 2. The strand including an organic fiber, a recycled synthetic fiber, or a combination thereof may have one or more properties which are similar to those of strand(s) used to form the cores described with respect to FIGs. 1 and 2. For brevity, the description provided with respect to FIGs. 1 and 2 is not repeated here. [0056] FIG. 3 schematically shows a composite yarn 300. The composite yarn 300 has a core-sheath structure including a core 310 and a sheath 320. In some embodiments, the composite yarn has a linear density from 50 dTex to 1000 dTex (100 Tex), from 50 dTex to 200 dTex, from 100 dTex to 500 dTex, or from 250 dTex to 1000 dTex. A standard method test method, such as an ASTM test method, may be used to determine the linear density of the fibers and the yarns described herein.

[0057] In the example of FIG. 3, the core 310 includes a cellulose-based filament. The cellulose-based filament may be a regenerated cellulose filament, such as a lyocell filament. The core may include a single cellulose-based filament or multiple cellulose-based filaments. The individual filaments of the core 310, such as lyocell filaments, may have a linear density from 1 dTex to 10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3 dTex, from 5 dTex to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex to 50 dTex. The core may include a fewer number of fibers when each filament has a higher linear density. The filament(s) of the core 310 may provide at least 2% and up to 5%, 10%, or 15% of the yarn while the fibers of the sheath 320 may make up the remainder of the yarn.

[0058] In some cases, the core 310 may also include a synthetic filament, such as a recycled synthetic filament or an elastomer fiber (recycled or virgin). For example, the core 310 may include one or more synthetic elastomer fibers, such as spandex or elastane filament fibers. The elastomer fiber may be a polyurethane elastomer (e.g., a segmented polyurethane elastomer), a cross-linked polyacrylate, or a combination of a polyurethane elastomer with another polymer, such as nylon. In some cases, the spandex fiber may be a bio-based spandex or a post-industrial recycled spandex. The amount of the elastomer filament may be from 1 % to less than 10% by weight, from 1 % to 8% by weight, or from 2% to 7% by weight of the core or of the yarn. The core may also include a recycled synthetic filament which is not substantially elastomeric, such as a recycled nylon filament.

[0059] Typically, the sheath 320 includes fibers in staple form which are intimately mixed and interlocked. Typically, the staple fibers are twisted around the core 310. When the filaments in the core are twisted, the staple fibers may be twisted in the opposite direction. The sheath may be formed around the core using a core spinning technique, such as a ring spinning technique or a friction spinning technique. However, other spinning techniques, such as rotor spinning techniques, air jet techniques, and the like may also be used.

[0060] The sheath 320 typically includes one or more organic fibers. The sheath may also include a synthetic fiber in staple form, although this is not necessary nor present in all embodiments. In some embodiments, the amount of the synthetic fiber(s) in the sheath is less than that of the organic fiber(s), so that the sheath predominantly includes organic fibers. For example, the amount of the synthetic fiber may be less than or equal to 40%, 30%, 20%, 10%, or 5% by weight of the sheath fibers. As examples, the synthetic fiber may include one or more of nylon, polyester, acrylic, and the like.

[0061] FIG. 3 shows composite yarn 300 as having a single ply. In additional examples, the composite yarns include multiple plies. For example, multiple plies may be twisted together to obtain a desired yarn thickness, linear density, and/or mechanical property. The yarn 300 may be used to form a textile by a weaving or knitting operation and the yarn properties may be adjusted for the particular weaving or knitting operation.

[0062] FIG. 4 shows a detail view of the sheath 420 of the yarn 400, which is an example of detail region 1-1 of the yarn 300 of FIG. 3. As shown in FIG. 4, the sheath 420 of the yarn 400 includes a blend of two different types of fibers, a first fiber 412, which is an organic fiber, and a second fiber 416, which is different from the first fiber; the second fiber may also be organic in many embodiments. The first fiber 412 and second fiber 416 may be in staple form.

[0063] For example, the first fiber 412 may include a wool fiber, such as a merino wool fiber. The wool fiber may have an average diameter less than 24 microns, less than 20 microns, or even less than or equal to 17.5 microns.

[0064] In some embodiments, the second fiber 416 may be an organic staple fiber different from the first fiber 412. As an example, the second fiber 416 may be a cellulose- based staple fiber such as a lyocell staple fiber. In some embodiments, the cellulose-based fibers have a linear density from 1 dTex to 3 dTex. For example, the amount of a wool fiber may be at least 40%, 50%, 60%, or 70% by weight of the sheath 420. The amount of the wool fiber may be greater than or equal to the amount of the cellulose-based staple fiber or the amount of the cellulose-based staple fiber may be greater than or equal to the amount of the wool staple fiber. The amount of the wool fiber and the amount of the cellulose-based staple fiber together may make up at least 80%, 90%, or 95% by weight of the sheath.

[0065] Alternately, the second fiber 416 may be a synthetic fiber in staple form. For example, the synthetic fiber may include one or more of a nylon fiber, a polyester fiber, an acrylic fiber, and the like. The synthetic fiber may be a recycled synthetic fiber. In some embodiments, the synthetic fiber has a linear density from 1 dTex to 5 dTex. For example, the amount of the wool fiber may be at least 40%, 50%, 60%, or 70% by weight of the sheath. In some cases, the amount of the wool fiber may be greater than or equal to the amount of the synthetic fiber. The amount of the wool fiber and the amount of the synthetic fiber together make up at least 80%, 90%, or 95% by weight of the sheath. [0066] In some embodiments, the yarn may be made of the following fibers: 48% lyocell; 21% wool; 15% nylon (including recycled nylon); 7% polyester (including recycled polyester); and 2% spandex. In other embodiments, the yarn may be made of the following fibers: 47% lyocell; 21% wool, 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 12% polyester (including recycled polyester, such as 6% recycled polyester and 6% unrecycled polyester); and 2% spandex. In still other embodiments, the yarn may be made of the following fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester (including unrecycled polyester, such as 4% recycled polyester and 4% unrecycled polyester); and 2 % spandex. It should be appreciated that the percentages given may be by weight, density, volume, or any other appropriate characteristic (as may any set of percentages discussed herein).

[0067] FIG. 5 shows an example of the composite yarn of FIG. 3, with a portion of the yarn 500 cut away to show the core 510 and the sheath 520. For the purposes of illustration, the core 510 is shown as forming a substantial portion of the composite yarn. However, the example of FIG. 5 is not limiting and the core may form 50% or less, 40% or less, 30% or less, 25% or less, 20% or less, 15% or less, or 10% or less by weight of the yarn.

[0068] As shown in FIG. 5, the sheath 520 substantially covers the core 510. However, it is not necessary that the sheath completely cover the core. For example, the coverage of the core by the sheath may be from 70% to 100%, from 80% to 100%, or from 90% to 100%. The level of coverage may be determined using an image analysis technique. Substantially central placement of the core 510 within the sheath 520, as shown in FIG. 5, can facilitate coverage of the core 510 by the sheath 520.

[0069] The core 510 may include a cellulose-based filament as previously described with respect to FIG. 3. In some embodiments, the core 510 may have a linear density from 25 dTex to 150 dTex and may include multiple cellulose-based filaments. The individual filaments, such as lyocell filaments, may have a linear density from 1 dTex to 10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3 dTex, from 5 dTex to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex to 50 dTex. The cellulose-based filaments in the core may be twisted together.

[0070] In some cases, the core 510 may include a synthetic filament, such as a recycled synthetic filament or an elastomer fiber (recycled or virgin). The discussion of recycled synthetic filaments and elastomer fibers provided with respect to FIG. 3 is generally applicable herein and, for brevity, is not repeated here. [0071] FIG. 6 shows an additional example of composite yarn 600 having a core-sheath structure. The core 610 includes multiple cellulose-based filaments 618. The sheath 620 includes organic fibers 622, such as wool fibers. As schematically shown in FIG. 6, the organic fibers 622 are generally twisted around the core 610 but some of the ends of the organic fibers 622 may project outward from a central portion of the core. The organic fibers 622 may be staple fibers. As previously discussed, in some cases the sheath may include at least two different types of fibers, with the first type of fiber being a wool fiber and the second type of fiber being a different organic fiber or a synthetic fiber. The cellulose-based filaments 618 of core 610 and the organic fibers 622 of the sheath 620 may be similar in composition, linear density, and other physical properties to the cellulose based filaments and the organic fibers previously described with respect to FIGs. 4 and 5 and, for brevity, that description is not repeated here.

[0072] The composite yarns described herein can be used to form woven or knitted textiles. The textile may be formed solely from the composite yarns of the present disclosure or may be formed from a combination of the composite yarns with one or more additional yarns. In some embodiments, the additional yarn may have a size comparable to or less than that of the composite yarn. Knitted (or knit) textiles have a knitted (or knit) structure which includes intermeshed loops.

[0073] As previously discussed, the composite yarns described herein may allow the production of finely knit textiles. For example, these composite yarns can be knitted on knitting machines having at least 30 needles per inch (30 gauge) and up to and including 48 needles per inch (48 gauge). The knitted structure (or knit structure) of the textile may be described by the gauge (e.g., 30 gauge to 48 gauge) or alternately by the stitch density. The knit textile may be formed by a weft knitting or by a warp knitting process.

[0074] The knitted textiles may have a stretch property such as two-way stretch (extending in one direction), four-way stretch (extending in crosswise and lengthwise directions), or equal stretch in all directions. For example, the textile may have a stretch property due to the knitted structure, such as in a single or double jersey. In addition, the textile may have a stretch property due to incorporation of elastomeric yarns in the textile. The elastomeric yarn may include one or more synthetic elastomer filaments, such as spandex or elastane filaments. The elastomer filament may be a polyurethane elastomer (e.g., a segmented polyurethane elastomer), a cross-linked polyacrylate, or a combination of a polyurethane elastomer with another polymer, such as nylon. In some embodiments, the elastomeric yarn may be a “bare” elastomer yarn, such as a spandex yarn. In additional embodiments, the elastomeric yarn may be a covered yarn having a core including an elastomeric filament and a sheath including an organic fiber, a synthetic fiber, or a combination thereof.

[0075] In some embodiments, all or a portion of the textile may be made of the following fibers: 48% lyocell; 21% wool; 15% nylon (including recycled nylon); 7% polyester (including recycled polyester); and 2% spandex. In other embodiments, all or a portion of the textile may be made of the following fibers: 47% lyocell; 21% wool, 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 12% polyester (including recycled polyester, such as 6% recycled polyester and 6% unrecycled polyester); and 2% spandex. In still other embodiments, all or a portion of the textile may be made of the following fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester (including unrecycled polyester, such as 4% recycled polyester and 4% unrecycled polyester); and 2 % spandex. It should be appreciated that the percentages given may be by weight, density, volume, or any other appropriate characteristic (as may any set of percentages discussed herein). [0076] The disclosure also provides articles formed from the textiles disclosed herein.

For example, the textiles may be included in a clothing article. A clothing article may be a garment, such as a shirt, a pair of pants, a pair of leggings, a sweatshirt, a jacket, socks, and the like. A clothing article may also be an undergarment, such as a pair of underwear or a bra. Clothing articles, such as garments or undergarments, may be suitable for use as activewear or sportswear. The textiles may also be included in a footwear article, such as a shoe.

[0077] The textiles disclosed herein may also be included in other types of articles. For example, the textile may be included in an accessory, such as a tote bag, handbag, or drawstring bag. Further, the textile may be included in a household good, such as a sheet, a bath towel, a dish towel, a tablecloth, an upholstered furniture article, and the like.

[0078] FIG. 7 shows an example of a shoe 700 including a composite yarn as described herein. The composite yarn is included in knitted textile 760. Shoe 700 can have a greater percentage of renewably sourced materials than some conventional shoes due to the high percentage of organic fibers and filaments in the composite yarn. In addition, the shoe 700 can have a desirable appearance, “feel,” and so forth due to the organic fiber(s) in the sheath of the composite yarn.

[0079] As shown in FIG. 7, the knitted textile 760 is included in the upper 710 of the shoe 700. In additional examples, the knitted textile 760 may be included in other parts of the shoe 700, such as the tongue 730 or the liner 770. As shown in FIG. 7, the shoe 700 also includes a sole 720, eyelets 740, and a lace 750.

[0080] FIG. 8 shows an example of a pair of leggings 800 which includes a composite yarn as described herein. The composite yarn is included in a textile 860 having a knitted structure. The textile 860 has a stretch property due to the knitted structure. In some embodiments, the knitted structure includes an elastomeric yarn in addition to the composite yarn.

[0081] The textile 860 may be finely knit and may have a fine gauge. The knitted structure of textile 860 can help provide durability to the leggings 800. In addition, the knitted structure of textile 860 can maintain opacity (e.g., prevent “show-through”) in areas which may be stressed by the movement or position of a wearer, such as the knees or the seat of the leggings 800.

[0082] Leggings including the composite yarns disclosed herein can have a greater percentage of renewably sourced materials than some conventional leggings which are knit wholly from synthetic yarns. Therefore, leggings including the textiles disclosed herein can have a reduced environmental impact as compared to some conventional leggings. In addition, the leggings 800 can have the desirable appearance, “feel,” and so forth due to the organic fiber(s) in the sheath of the composite yarn. For example, wool fibers in the sheath of the composite yarn can give moisture wicking properties to the leggings.

[0083] FIGs. 9A and 9B illustrate sample garments formed from composite yarns as disclosed herein. In particular, FIGs. 9A and 9B illustrate socks that may be formed from any of the yarns described herein, including combinations of various yarns described herein and/or more conventional yarns (such as cotton or wool).

[0084] FIG. 9A illustrates a low-rise sock 900 including a heel retaining feature 905, a front retaining feature 910, and an elastic feature 915. Any or all of the body 916 of the sock 900 (e.g., the portion of the sock excluding the heel retaining feature 905 and front retaining feature 910), the front retaining feature 910, and the heel retaining feature 905 may be formed from any yarn described herein. Further, different parts of the sock 910 may be formed from different yarns. As one non-limiting example, the elastic feature 915 may be formed from a yarn including lyocell and wool, but having a greater percentage of spandex than the rest of the sock 900. Likewise, the heel retaining feature 905 and/or the front retaining feature 910 may be formed from a yarn having lyocell and wool fibers, but in different percentages, or including polyester and/or nylon (whether virgin or recycled) in different percentages, than another portion of the sock 900. In this fashion the heel retaining feature 905 and front retaining feature 910 may be more durable, less (or more) stretchable, or otherwise have different material properties than other parts of the sock 900. As yet another example, portions of the sock may have different knit or weave patterns than other parts of the sock. Different numbers of ends, densities, stitches, or the like may be used to vary material properties even if the same yarn is used throughout the sock 900 (or throughout different portions of the sock, including the retaining features 905, 910 and/or elastic feature 915). As one non-limiting example, the knit or weave of the sock may vary in the elastic feature 915 as opposed to the rest of the sock in order to increase stretch in the elastic feature, thereby enhancing the ability of the sock to remain in place on a wearer’s foot without unduly shifting.

[0085] FIG. 9B illustrates another example sock 920 that may be formed from any suitable yarn described herein, or a combination of yarns described herein, or one or more yarns described herein and one or more of wool, cotton, and/or lyocell yarns. The sock 920 includes a calf retaining feature 925, a heel 930, and an elastic portion 935. Here, the calf retaining feature 925 may be similar in composition, structure, and/or other facets of construction as either the front retaining feature 910 and/or heel retaining feature 905 of the sock 900 illustrated in FIG. 9A. Likewise, the body 940 of the sock 920 may be made of the same or similar yarn as the body 916 of the sock 900 and the elastic portion 935 may be similar in composition, structure, or the like to the elastic portion 915 of FIG. 9A.

[0086] The calf retaining feature 925 may be knitted, woven, or otherwise formed in such a fashion that an elasticity of the feature 925 is enhanced as compared to a body of the sock 920, thereby permitting the sock 920 to stay “up” while worn. The yarn used to form the calf retaining feature 925 may likewise be the same as that of the body of the sock 920, or it may be made of the same or similar fibers in different proportions. Typically, however, the yarn itself is the same throughout the sock 920 (and, for that matter, the sock 900) while the weave or knit pattern varies and/or different yarns are added in particular areas such as the retaining feature(s).

[0087] Likewise, the heel 930 may be reinforced or may be formed from a yarn that is made from the same fibers as the rest of the sock 920 but in different percentages to strengthen the heel relative to the rest of the sock. In some embodiments, however, this is not the case.

[0088] In certain embodiments, the yarn used to form the sock 900, 920 may vary with a shape, height, or structure of the sock 900, 920. For example, the sock 900 shown in FIG. 9A may be formed from a yarn having the following fibers in the following percentages: 48% lyocell; 21% wool; 15% nylon (including recycled nylon); 8% polyester (including recycled polyester); and 2% spandex. With respect to the sock 920 shown in FIG. 9B„ the yarn may be made of the following fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester (including unrecycled polyester, such as 4% recycled polyester and 4% unrecycled polyester); and 2 % spandex.

A low-rise sock may be formed from a yarn made of the following fibers: 47% lyocell; 21% wool, 18% nylon (including recycled nylon, such as 17% recycled nylon and 1% unrecycled nylon); 12% polyester (including recycled polyester, such as 6% recycled polyester and 6% unrecycled polyester); and 2% spandex. As mentioned above, the specific percentages given here may be by weight, density, volume, or any other suitable measurement.

Likewise, although particular percentages have been provided, it should be understood that any or all of the above percentages, with respect to any of the embodiments, may vary by as much as 3% in either direction in absolute terms, or by as much as 20% in relative terms.

[0089] Although some of the foregoing embodiments are discussed with respect to compositions by weight, it should be understood that the same percentages and ranges may apply to compositions by volume, number, or density in other embodiments. This applies to any and all of the embodiments, percentages, and/or ranges disclosed herein.

[0090] As used herein, the term “substantially” or "about"' is used to account for relatively small variations, such as a variation of +/- 10%, +/- 5%, +/- 2%, or +/- 1%. The term "substantially free" may indicate an amount of 10% or less, 5% or less, 2% or less, or 1% or less of the element specified. In addition, the singular forms "a," "an," and "the" include the plural form unless the context dictates otherwise.

[0091] As used herein, the phrase "one or more of" preceding a series of items, with the term “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase "one or more of" does not require selection of at least one of each item listed; rather, the phrase allows a meaning that includes at a minimum one of any of the items, and/or at a minimum one of any combination of the items, and/or at a minimum one of each of the items. By way of example, the phrases “one or more of A, B, and C” or “one or more of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or one or more of each of A, B, and C. Similarly, it may be appreciated that an order of elements presented for a conjunctive or disjunctive list provided herein should not be construed as limiting the disclosure to only that order provided.

[0092] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.