Field of the Invention

The present invention relates to a yam which comprises a high-strength material for enhancing the resilience of the core against cutting, a wool fiber-containing covering for aesthetic and comfort around the core, and wherein the wool fiber it comprises is blended with a flame retardant fiber in order to provide flame retarding feature, and a fabric produced from the said yam.

Background of the Invention

The intended field of use in fabrics with cutting resistance that are developed in the textile sector is for the use of individuals who want to use them for purposes such as law enforcement and personal protection, especially because they serve as personal security and armor. Various applications in order to provide protection against pointed and sharp objects such as knives in textile products are present in the state of the art, however the main problem in these products is not being able to provide comfort feature aside from protection. Accordingly, decrease in thermophysiological comfort of the users makes difficult to wear the textile product as long term clothes. In addition to comfort features, there is no source in the literature that both resistance against cutting and flame retarding ability can be provided in textile products.

When the products present in the market are examined, for example production is made in form of a woven fabric form directly with high performance yarn in protective gloves, or yam forms are prepared by folding technique with high performance yarn, and woven fabric production made. When the protective clothes are examined, they are produced and used in folded forms, i.e. one layer is produced by weaving and/or knitting technique with a performance yarn and the other layer is produced by weaving or knitting as the surface wanted to be used. US20050055997A1, an application known in the state of the art, discloses a composite twist core spun yarn.

US20030074879A1, an application known in the state of the art, discloses a composite twist core spun yarn and a fabric.

In the publication titled“Hybrid - from two different origins, blended and mixed”, an application known in the state of the art, discloses hybrid yarns obtained by combining materials from two different origins. ¹

In the state of the art, although there are various high performance fabrics which are resistant to cutting in the market, it is seen that there is not a commercial product formed for this purpose in the wool fabric sector.

Summary of the Invention

The objective of the present invention is to provide worsted fabrics which are both resistant to cutting and have flame retarding ability.

Another objective of the present invention is to provide core from a high strength material and worsted fabrics formed from yams having a wool fiber-flame retardant fiber blend covering located around the core.

Detailed Description of the Invention

“A flame retardant yarn with cutting resistance and a fabric comprising thereof’ developed in order to obtain the objectives of the present invention is illustrated in the accompanying drawing, wherein

¹ https://www.schoeller-wool.com/34738/Products/Technical-yarn s/Hybrid- y arns/index_group . aspx Figure 1 shows the schematic view of Cirro core yarn spinning system used during the production of the inventive core yarn.

The components shown in the figures are each given reference numbers as follows:

100. Core-spun yam production system

1. Roving

2. Filament

3. Roving condenser

4. Roving distance holder

5. Drawing cylinders

6. Filament guide

7. Core/yam spinning

8. Corrugated cylinder

9. Twist adjustment mechanism

10. Core yarn

11. Ring spinning

The invention relates in particular to the yarn formed by using core yam spinning method, comprising a filament of high strength material to increase the resistance of the core against cutting, comprising a covering comprised of wool fibers for aesthetic and comfort around the core, and a fabric produced from the said yarn. Within the scope of the object, at least one high resistance material selected from the group consisting of high tenacity polyamide 6.6, high tenacity Polyester and combinations therefore is used as core part of the yarn. In one embodiment of the invention, the wool fiber around the core is blended with a flame retardant fiber in order to provide flame retardancy to the yarn/fabric. The yarn structure according to the invention, which has both resistance against cutting and flame retardancy features by means of the suitable fiber mixing ratios, is used in worsted fabrics. Worsted fabrics, which provide production opportunity for high quality suit fabrics, constitute the predominant production of Yiinsa; the work has been done on worsted fabrics. With the production of worsted yarn, thermal comfort and desired holding characteristics can be acquired and also it allows the user to use in 4 seasons. The wool is hygroscopic in nature and can absorb water in ratios up to 40% and even in this case the wool may not feel damp. Its elongation rate increases up to 60% in wet (damp) state. Because its molecular chains are loosened by the moisture entering into the transverse bridges and the elongation against force increases; for this reason, it provides comfort to the user in terms of use. In addition, wool has the largest elastic-elongation among natural fibers; its elasticity value is 100% when a force that is half of the breaking force is applied. That is, it returns to its first form again when the force is removed. Practically, it does not exhibit permanent elongation. With these features, it can provide user comfort, holding and thermal comfort.

Core yarn production in ring yarn machine within the scope of the invention is performed by feeding the filament in the core by the pre-conveying cylinders during spinning process and placing in core part of the roving that is being drawn. The conveying cylinder ensures that the spinning is carried out properly and enables the core filament always to remain in the core. By this means, the filament in the core is continuously wound by the covering fibers and remains in the inner side of the yam. The filament in the core is wound by the staple fibers and placed in the core part of the yam by means of twisting and winding processes. With this method, weaving constructions have been designed with core yam formed by feeding high performance yarn to the wool rovings, it has become as the final fabric by applying routine production processes. In addition to fabrics obtained by feeding into the wool rovings, it has been also fed into rovings having different blending ratios of wool/polyester, and positive results have been obtained. For this reason, wool and blending ratios comprising wool (for example wool/polyester, wool/nylon and wool/animal fiber (cashmere, alpaca, mohair, silk) can also be used. When the test result of the obtained samples are compared to normal values, breaking strength up to 3 times, shear strength up to 3 to 4, shifting value of stitching yarns up to 2 times, and abrasion value up to 2 times have been acquired. Additionally, it has passed the blade cut resistance test, and it has no difference from the wool products in terms of aesthetic and comfort.

The process chart of the core-spun yarn production (Worsted yarn spinning process steps) can be stated under these titles:

Worsted yam spinning:

1) Fiber (tops): In worsted yam system, wool band heckled in heckling machine is called tops in production. It enables the short fiber that is not possible to control in the band in combing process to be eliminated, the fibers to be considerably parallel, and the fiber distribution to be homogenous. The quality of tops forming the starting raw material of yarn production directly affects the characteristics and quality of the yarn to be produced.

2) Melanger: Blending of tops so that a homogenous fiber mixture will be present in the yarn to be produced or making different raw material tops in order to produce colored yarn are realized in the said process.

3) Passage drawing (1-2-3): The drawing process is the process of reducing the mass of the band per unit length. In this process, a homogeneous structure is formed by doubling bands or strips first. Then they are thinned by drawing.

4) Combing (comber): In order to obtain a proper yarn with a compact surface, it is necessary to make the fibers fully parallel to the band axis or to one another. In order to separate and remove fibers which are shorter than a certain length for yarn strength and smoothness, the process of eliminating fiber nodes and vegetal foreign materials called "nope" is intended and realized.

5) Preparation drawing: Drawing and doubling processes are realized. The only different operation of the preparation drawing from the other drawings is to ensure that the number of bands drawn with a regulator integrated into the machine is of the specified value.

) Rovings: Thin fiber strips formed as a result of thinning of the band as a final preparation for yarn spinning and the process that is performed are called roving. The band is brought to the roving thinness that can be worked on the spinning machine after the drawing. The thinned roving is provided with strength by twisting with the rubbing technique.

) Ring yarn spinning: Process is performed in Ring Yarn machines in order to obtain yarn in number and resistance suitable for the place where it is used by thinning the roving coming from the roving machine by means of drawing, to provide the desired twist, and wind the said yarn in cop form.) Fixing: The yam has internal tensions in spinning processes. It is the process performed in order to form relaxed structure by eliminating internal tensions causing irregular orientation and shapes in the yarn. The most important purpose of the fixing is to provide stability to the product to which it is applied.

) Winding: In order to use the yarns, bobbins must be made from them, the bobbins are formed from the cops for this reason, the defects on the yarn are removed while the bobbin is being formed, the machine efficiency increases with the yarn winding in long meters and thus the cost is reduced, and the operation comfort in the weaving circle is ensured.

0) Preparation to weaving: It is a preparatory stage comprised of a number of processes such as warp preparation, drawing, sizing and weft preparation before weaving process. It is number of processes that can vary depending on the construction to be woven.

1) Weaving: They are obtained by forming a fabric by means of bonding two groups of yarns intersected with each other in a vertical direction to each other in a pattern called mesh during this intersection The basic characteristics of obtained surfaces determined as smooth surface, fineness, aesthetics, flexibility, durability, covering feature exhibit significant changes depending on the fabric structure. 12) Pre-finish: It is the general name of the processes of removing foreign materials in the product performed as preparation for finishing processes in order to enhance the aesthetic appearance of the product.

13) Finish process: It is a series of chemical and mechanical processes to improve the appearance, holding and handling properties of textile products as desired, except whitening and coloring.

14) Quality control: It is the processes which are performed in order to control whether the manufactured product has the desired quality.

15) Performance evaluation: It is the process of comparing the product manufactured as a result of the design with the expected performance level. The tests carried out in the design are Breaking Strength, Tear strength, Seam slippage, Martindale Abrasion, Pilling, Blade cut resistance, Horizontal burning.

In order to provide flame retardancy feature to the composite yarn structure formed within the scope of the invention, additional raw material having flame retardancy feature and the compatible fiber fineness and length is included during tops phase. Therefore, high performance textile products with both flame retardancy and cutting strength properties can be formed by using wool obtained within the scope of the invention and comprising both flame retardant raw material and high performance raw material. The product does not negatively affect the thermophysiological comfort of the user and does not prevent the user from wearing clothes for a long time.

User aesthetic demand and touching features can be provided only by producing as the core component in core-spun yarn production. Fabric surfaces can be formed and glued to each other with the lamination technique and thus protective surfaces can be obtained, but this time the parameters of lamination material and technique will have negative effects. Furthermore, it will not have the same weight, permeability characteristics as a casual outfit that the user can use all the time. When the flame retardancy property is evaluated, the wool fabric can be enhanced with the finishing application, however this can be limited to a specific number of washing. For this reason, the flame retardancy property can be obtained by means of the raw material. It is possible to achieve even higher values with the addition of flame retardant raw material in the wool, LOI (Limit Oxygen Index) value of which is 24-25, and thus to provide permanent flame retardancy. The raw material that can be supplied with the wool can be Acrylic, Polyester, Polyimide that is provided with Fr characteristic. The LOI values of them are 40, 28, 30-32, respectively. The reason for preferring them it has a fineness and length property suitable for the wool top. The range functioning as wool top is 2.4-2.7 dtex fineness and 75-88 mm length. All of the supplied raw materials are within these properties.

Within the scope of the preliminary studies carried out during the development of the invention, first UHMWPE (polyethylene with ultra-high molecular weight) yarns were supplied and woven fabric was produced based on the construction of a classic quality in the direction of weft and warp in wool fabrics. However, it was observed that the obtained fabric is not suitable in terms of touching and user performance. As a result of these preliminary studies, it has been concluded that the said fibers should be covered with wool fiber by using the core spinning technique in the ring spinning machine so as to remain in the core filament yam center during spinning. Yarn production was carried out by using high resistance raw material as core component in core-spun yarn production, and woven fabrics were produced with the suitable weaving constructions. In the obtained woven fabrics, it was provided that worsted fabrics having the touching of classical high performance wool fabric having cutting resistance were developed. In addition to these properties, in order to provide flame retardancy property, wool fiber in fiber (top) form was provided with flame retardancy by blending with a fiber having a fineness and length compatible with wool fiber which has a flame retardancy feature. The most ideal method for designing a product which both has aesthetic and comfort characteristics demanded by the user and the cutting resistance is the core-spun yarn production. Within the scope of the invention, longer service life with higher performance is achieved, and thus sustainability is provided. A product which is light-weight and soft, the aesthetic properties of which is preserved, and which also has high performance and flame retardancy properties is provided. The objective is to eliminate the negative aspects known in the state of the art, and provide technical and high performance properties desired to be obtained in addition to the aesthetic and comfort properties, and it is achieved by means of the invention. Within this scope, by means of producing wool composite yarns and design of suitable constructions, high performance fabrics having cutting resistance (tear strength, breaking strength, resistance against stitch shift, abrasion resistance, and the like) are obtained. In addition to these properties, in order to provide flame retardancy property, wool fiber in fiber (top) form was provided with flame retardancy by blending with a fiber having a fineness and length compatible with wool fiber which has a flame retardancy feature.