Yarn of staple fibers from multi-filaments by stretching and controlled breaking and articles made therefrom

Abstract

A single-strand yarn includes a plurality of intimately associated staple fibers made from N strands of multi-filaments by stretching and controlled breaking, and then spun by a spinning process, where N is a natural number. Within the single-strand yarn of a sampling length according to the invention, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length to the total number of the staple fibers, is equal to or greater than 60%. The sampling length is equal to or less than 10 meters. The setup fiber length is equal to or larger than 65 mm. The dispersion of the weight distribution in the average length of the single-strand yarn according to the invention is equal to or less than 60%.

What is claimed is: 
     
         1 . A single-strand yarn, comprising:
 a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number,   wherein within said single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said single-strand yarn is equal to or less than 60%,   wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.   
     
     
         2 . The single-strand yarn of  claim 1 , wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of said single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, said single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength. 
     
     
         3 . A plied yarn, comprising:
 M single-strand yarns, being doubled or twisted together, M being an integer equal to or larger than 2, each single-strand yarn comprising:   a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number,   wherein within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%,   wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.   
     
     
         4 . The plied yarn of  claim 3 , wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of said single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, said single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength. 
     
     
         5 . A textile article woven from a first single-strand yarn or a plied yarn by one selected from the group consisting of a weaving process, a non-weaving process, a knitting process, a warp knitting process, and a weft knitting process, the plied yarn comprising M second single-strand yarns which are doubled or twisted together, M being an integer equal to or larger than 2, the first single-strand yarn and each second single-strand yarn both comprising:
 a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number,   wherein within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%,   wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.   
     
     
         6 . The textile article of  claim 5 , wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of the first single-strand yarn or each second single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, the first single-strand yarn and each second single-strand yarn both have a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength. 
     
     
         7 . The textile article of  claim 6 , wherein a number of neps on a surface of the textile article is equal to or less than 30/m 2 . 
     
     
         8 . The textile article of  claim 7 , wherein the N strands of first multi-filaments are made of 316L stainless steel, the textile article is woven by the knitting process.