Treatment of filament yarns to provide spun-like characteristics and yarns and fabrics produced thereby

Abstract

A continuous filament yarn having characteristics of a spun yarn. The filament yarn includes an arrangement of elongate polymeric filaments of extended length intermingled to form a cohesive yarn structure. At least a portion of the elongate filaments disposed at the exterior surface of the cohesive yarn structure are broken filaments disposed at discrete locations along the yarn. Fabrics formed from such continuous filament yarns are also provided.

That which is claimed is:  
     
         1 . A continuous filament yarn adapted to mimic a spun yarn, the continuous filament yarn comprising: 
 a plurality of elongate polymeric filaments of extended length intermingled to form a cohesive yarn structure, wherein the cohesive yarn structure comprises an interior and an exterior surface, and wherein at least a portion of the elongate filaments disposed at the exterior surface of the cohesive yarn structure are broken filaments disposed in circumferentially wrapped relation at least partially around the interior such that terminal ends of the broken filaments define an arrangement of outwardly projecting hairs and wherein the outwardly projecting hairs project away from the interior at discrete locations disposed substantially around the circumference of the cohesive yarn structure.    
     
     
         2 . The invention as recited in  claim 1 , wherein the cohesive yarn structure is an air-jet entangled yarn.  
     
     
         3 . The invention as recited in  claim 1 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 10,000 denier  
     
     
         4 . The invention as recited in  claim 3 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 70 to about 350 denier.  
     
     
         5 . The invention as recited in  claim 3 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 400 denier to about 1000 denier.  
     
     
         6 . The invention as recited in  claim 3 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 1500 denier to about 3000 denier.  
     
     
         7 . The invention as recited in  claim 1 , wherein the cohesive yarn structure is a core and effect air jet entangled yarn.  
     
     
         8 . The invention as recited in  claim 7 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 70 denier to about 10,000 denier  
     
     
         9 . The invention as recited in  claim 8 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 70 to about 350 denier.  
     
     
         10 . The invention as recited in  claim 8 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 400 denier to about 1200 denier.  
     
     
         11 . The invention as recited in  claim 8 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 1500 denier to about 3000 denier.  
     
     
         12 . The invention as recited in  claim 1 , wherein the cohesive yarn structure is a false twist texturized yarn.  
     
     
         13 . The invention as recited in  claim 12 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 1500 denier  
     
     
         14 . The invention as recited in  claim 13 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 70 to about 350 denier.  
     
     
         15 . The invention as recited in  claim 13 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 400 denier to about 1000 denier.  
     
     
         16 . The invention as recited in  claim 1 , wherein at least a portion of the plurality of elongate polymeric filaments have a denier per filament rating of not greater than about 0.6 denier per filament.  
     
     
         17 . The invention as recited in  claim 1 , wherein at least a portion of the plurality of elongate polymeric filaments are selected from the group consisting of solution dyed polyester filaments, package dyed polyester filaments, PLA filaments, nylon filaments, polypropylene filaments, nomex filaments and kevlar filaments.  
     
     
         18 . A continuous filament yarn adapted to mimic a spun yarn, the continuous filament yarn comprising: 
 a plurality of elongate polymeric filaments of extended length intermingled to form a cohesive yarn structure, wherein the cohesive yarn structure comprises an interior and an exterior surface, and wherein a first portion of the elongate filaments disposed at the exterior surface of the cohesive yarn structure are broken filaments disposed in circumferentially wrapped relation at least partially around the interior such that terminal ends of the broken filaments define an arrangement of outwardly projecting hairs and wherein the outwardly projecting hairs project away from the interior at discrete locations disposed substantially around the circumference of the cohesive yarn structure, and wherein a second portion of the elongate filaments disposed at the exterior surface of the cohesive yarn structure are kinked along their length so as to define sharp radius loop projections projecting away from the interior.    
     
     
         19 . The invention as recited in  claim 18 , wherein the cohesive yarn structure is an air-jet entangled yarn.  
     
     
         20 . The invention as recited in  claim 19 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 600 denier.  
     
     
         21 . The invention as recited in  claim 18 , wherein the cohesive yarn structure is a core and effect air jet entangled yarn.  
     
     
         22 . The invention as recited in  claim 21 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 600 denier.  
     
     
         23 . The invention as recited in  claim 18 , wherein the cohesive yarn structure is a false twist texturized yarn.  
     
     
         24 . The invention as recited in  claim 23 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 600 denier.  
     
     
         25 . A fabric having a pair of substantially opposing faces, the fabric comprising: 
 a coordinated arrangement of yarns disposed in interlocking relation to one another wherein at least a portion of the yarns are continuous filament yarns adapted to mimic a spun yarn, the continuous filament yarns comprising a plurality of elongate polymeric filaments of extended length intermingled to form a cohesive yarn structure, wherein the cohesive yarn structure comprises an interior and an exterior surface, and wherein at least a portion of the elongate filaments disposed at the exterior surface of the cohesive yarn structure are broken filaments disposed in circumferentially wrapped relation at least partially around the interior of the cohesive yarn structure such that terminal ends of the broken filaments define an arrangement of outwardly projecting hairs and wherein the outwardly projecting hairs project away from the interior of the cohesive yarn structure at discrete locations disposed substantially around the circumference of the cohesive yarn structure such that said outwardly projecting hairs project away from the opposing faces of the fabric.    
     
     
         26 . The invention as recited in  claim 25 , wherein the cohesive yarn structure is an air-jet entangled yarn.  
     
     
         27 . The invention as recited in  claim 25 , wherein the cohesive yarn structure is a core and effect air jet entangled yarn.  
     
     
         28 . The invention as recited in  claim 25 , wherein the cohesive yarn structure is a false twist texturized yarn.  
     
     
         29 . The invention as recited in  claim 25 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 denier to about 10,000 denier  
     
     
         30 . The invention as recited in  claim 29 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 40 to about 350 denier.  
     
     
         31 . The invention as recited in  claim 29 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 400 denier to about 1000 denier.  
     
     
         32 . The invention as recited in  claim 29 , wherein the cohesive yarn structure is characterized by a linear density in the range of about 1500 denier to about 3000 denier.  
     
     
         33 . The invention as recited in  claim 25 , wherein the fabric is a woven fabric.  
     
     
         34 . The invention as recited in  claim 25 , wherein the fabric is a knit fabric.  
     
     
         35 . A Jacquard woven fabric including an arrangement of woven-in regions of enhanced profile disposed in raised relief relative to woven-in regions of lower profile such that said regions of enhanced profile define a woven-in pattern across at least one face of the fabric, the fabric comprising: 
 a coordinated arrangement of yarns wherein at least a portion of said yarns are texturized continuous filament yarns comprising a plurality of broken filaments projecting outwardly from said yarns at discrete locations disposed substantially around the circumference of said yarns.    
     
     
         36 . The invention as recited in  claim 35 , wherein at least a portion of said texturized continuous filament yarns are disposed within said regions of enhanced profile.  
     
     
         37 . The invention as recited in  claim 35 , wherein at least a portion of said texturized continuous filament yarns are disposed within said regions of lower profile.  
     
     
         38 . The invention as recited in  claim 35 , wherein at least a first portion of said texturized continuous filament yarns are disposed within said regions of lower profile and at least a second portion of said texturized continuous filament yarns are disposed within said regions of enhanced profile.  
     
     
         39 . A woven fabric including a face portion of variable hairiness, the fabric comprising: 
 a coordinated arrangement of yarns wherein a portion of said yarns are texturized continuous filament yarns comprising a plurality of broken filaments projecting outwardly from said texturized continuous filament yarns at discrete locations disposed substantially around the circumference of said texturized continuous filament yarns and wherein said texturized continuous filament yarns are disposed in woven relation within the fabric such that said texturized continuous filament yarns define substantially discrete regions of enhanced surface hairiness disposed in patterned relation with regions of relatively lower hairiness across the face portion of the fabric.    
     
     
         40 . A fabric comprising: 
 a coordinated arrangement of yarns wherein a portion of said yarns comprise a core portion of continuous elastomeric filaments and a surface portion of texturized filaments defining a plurality of broken filaments projecting outwardly away from said core portion at discrete locations disposed substantially around the circumference of said core portion.    
     
     
         41 . The invention as recited in  claim 40 , wherein said fabric is selected from the group consisting of woven fabric and knit fabric.  
     
     
         42 . A patterned knit fabric including an arrangement of knitted-in regions of enhanced profile disposed in raised relief relative to regions of lower profile such that said regions of enhanced profile define a knitted-in pattern across at least one face of the fabric, the fabric comprising: 
 a coordinated arrangement of yarns wherein at least a portion of said yarns are texturized continuous filament yarns comprising a plurality of broken filaments projecting outwardly from said yarns at discrete locations disposed substantially around the circumference of said yarns.    
     
     
         43 . The invention as recited in  claim 42 , wherein at least a portion of said texturized continuous filament yarns are disposed within said regions of enhanced profile.  
     
     
         44 . The invention as recited in  claim 42 , wherein at least a portion of said texturized continuous filament yarns are disposed within said regions of lower profile.  
     
     
         45 . The invention as recited in  claim 42 , wherein at least a first portion of said texturized continuous filament yarns are disposed within said regions of lower profile and at least a second portion of said texturized continuous filament yarns are disposed within said regions of enhanced profile.  
     
     
         46 . A continuous filament yarn comprising: 
 a plurality of outwardly projecting broken filament ends distributed at locations disposed around the circumference of the yarn wherein at least a portion of said broken filament ends are characterized by a length in excess of 2 mm.    
     
     
         47 . The invention as recited in  claim 46 , wherein the continuous filament yarn is an air-jet entangled yarn.  
     
     
         48 . The invention as recited in  claim 46 , wherein the continuous filament yarn is a false twist texturized yarn.  
     
     
         49 . A fabric comprising: 
 a plurality of continuous filament yarns wherein at least a portion of said continuous filament yarns comprise a plurality of outwardly projecting broken filament ends distributed at locations disposed around the circumference of the yarn and wherein at least a portion of said broken filament ends are characterized by a length in excess of 2 mm.    
     
     
         50 . The invention as recited in  claim 49 , wherein said fabric is a woven fabric.  
     
     
         51 . The invention as recited in  claim 50 , wherein said woven fabric is a flat woven fabric.  
     
     
         52 . The invention as recited in  claim 50 , wherein said woven fabric is a Jacquard woven fabric including an arrangement of woven-in regions of enhanced profile disposed in raised relief relative to woven-in regions of lower profile such that said regions of enhanced profile define a woven-in pattern across at least one face of the fabric.  
     
     
         53 . The invention as recited in  claim 49 , wherein said fabric is a knitted fabric.  
     
     
         54 . The invention as recited in  claim 53 , wherein said knitted fabric is a circular knit fabric.  
     
     
         55 . The invention as recited in  claim 53 , wherein said knitted fabric is a patterned knit fabric including an arrangement of knitted-in regions of enhanced profile disposed in raised relief relative to regions of lower profile such that said regions of enhanced profile define a knitted-in pattern across at least one face of the fabric.