Yarn and Method of Manufacturing Thereof

Abstract

Embodiments of the present invention are directed to a tri-core yarn including a core including an elastomeric filament, a first cover, and a second cover, and a fiber sheath covering the core, wherein the first cover and the second cover are each wrapped around the elastomeric filament.

What is claimed is: 
     
         1 . A tri-core yarn comprising:
 a core comprising:
 an elastomeric filament; 
 a first cover; and 
 a second cover; and 
   a fiber sheath covering the core,   wherein the first cover and the second cover are each wrapped around the elastomeric filament.   
     
     
         2 . The yarn of  claim 1 , wherein the first cover is wrapped in a first direction and the second cover is wrapped in a second direction. 
     
     
         3 . The yarn of  claim 1 , wherein the elastomeric filament, the first cover, and the second cover are twisted together. 
     
     
         4 . The yarn of  claim 1 , wherein the first cover and the second cover are different materials. 
     
     
         5 . The yarn of  claim 1 , wherein the elastomeric fiber is in a range of about 10 denier to about 300 denier. 
     
     
         6 . The yarn of  claim 1 , wherein the first cover comprises polyester or nylon. 
     
     
         7 . The yarn of  claim 6 , wherein the first cover is partially oriented yarn or fully drawn yarn. 
     
     
         8 . The yarn of  claim 1 , wherein the first cover is in a range of about 10 denier to about 600 denier. 
     
     
         9 . The yarn of  claim 1 , wherein the core is in a range of about 10 denier to 600 denier. 
     
     
         10 . The yarn of  claim 1 , wherein the fiber sheath comprises cotton, polyester, viscose, rayon, modal, lyocell, cupro, nylon, acrylic, wool, linen, hemp, ramie, and/or polyethylene. 
     
     
         11 . The yarn of  claim 1 , wherein the first cover yarn is wrapped around the elastomeric filament and the second cover yarn is wrapped around the first cover yarn. 
     
     
         12 . A method of manufacturing yarn, the method comprising:
 covering an elastomeric filament with a first cover yarn and a second cover yarn to form a core;   core-spinning the core to add a fiber sheath.   
     
     
         13 . The method of  claim 12 , wherein the covering of the elastomeric filament comprises:
 wrapping the first cover yarn around the elastomeric filament in a first direction; and   wrapping the second cover yarn around the elastomeric filament in a second direction.   
     
     
         14 . The method of  claim 12 , wherein the covering of the elastomeric filament comprises intermingling or air-covering the elastomeric filament with the first cover yarn and the second cover yarn. 
     
     
         15 . The method of  claim 12 , wherein the covering of the elastomeric filament comprises aligning the elastomeric filament, the first cover yarn, and the second cover yarn and twisting the elastomeric filament, the first cover yarn, and the second cover yarn together. 
     
     
         16 . A stretch fabric comprising a yarn, the yarn comprising:
 a core comprising:
 an elastomeric filament; 
 a first cover; and 
 a second cover; and 
   a fiber sheath covering the core,   wherein the first cover and the second cover are each wrapped around the elastomeric filament.   
     
     
         17 . The stretch fabric of  claim 17 , wherein a weft and a warp of the fabric comprise the yarn. 
     
     
         18 . The stretch fabric of  claim 16 , wherein the fabric comprises plain, poplin, twill, oxford, dobby, sateen and/satin fabric. 
     
     
         19 . The stretch fabric of  claim 16 , wherein the stretch fabric is configured to be stretched to between 10% and 100% of its original size in a warp direction.