Twisted yarns and methods of manufacture thereof

Abstract

A yarn is produced by twisting an organic yarn and a synthetic yarn. The organic and synthetic yarns and twisting processes thereof may be selected to produce a twisted yarn with enhanced performance characteristics such as moisture management, abrasion resistance, and refit. The twisted yarn may be knitted into articles of clothing such as socks.

1 . A method of forming a twisted yarn, the method comprising:
 twisting an organic thread comprised of organic staple fibers having a length of approximately 70 mm to 150 mm to have approximately 4 to 14 twists per inch;   twisting a synthetic thread comprised of synthetic fibers having a length ranging from approximately 28 mm to 132 mm to have approximately 6 to 16 twists per inch; and   twisting the organic thread and the synthetic thread together at an angle of approximately 15 to 65 degrees to form a twisted yarn, wherein the twisted yarn has approximately 20 to 35 twists per inch and a surface area with approximately a 50:50 ratio of organic staple fibers and synthetic fibers.   
     
     
         2 . The method of  claim 1 , wherein the organic staple fibers have a thickness ranging from approximately 16 microns to 28 microns. 
     
     
         3 . The method of  claim 1 , wherein the organic thread has a size of 1/54 NM. 
     
     
         4 . The method of  claim 1 , wherein the synthetic thread has a size of 1/32 NM. 
     
     
         5 . The method of  claim 1 , wherein the organic staple fibers comprises Merino wool staple fibers. 
     
     
         6 . The method of  claim 1 , wherein the organic staple fibers comprises model staple fibers. 
     
     
         7 . The method of  claim 1 , wherein the synthetic fibers comprises poly fibers. 
     
     
         8 . The method of  claim 1 , wherein the synthetic fibers comprises nylon fibers. 
     
     
         9 . The method of  claim 1 , wherein the synthetic fibers comprises acrylic fibers. 
     
     
         10 . The method of  claim 1 , further comprising twisting the organic thread in a first direction and twisting the synthetic thread in the first direction. 
     
     
         11 . The method of  claim 10 , further comprising twisting the organic thread and the synthetic thread in a second direction opposite the first direction. 
     
     
         12 . The method of  claim 1 , further comprising twisting a second organic thread with the organic thread prior to twisting the organic thread and the synthetic thread. 
     
     
         13 . The method of  claim 1 , further comprising twisting a second synthetic thread with the synthetic thread prior to twisting the organic thread and the synthetic thread. 
     
     
         14 . The method of  claim 1 , further comprising treating the synthetic thread with a hydrophilic treatment. 
     
     
         15 . The method of  claim 1 , further comprising treating the organic thread with a hydrophobic treatment. 
     
     
         16 . The method of  claim 1 , further comprising knitting the twisted yarn into a sock body. 
     
     
         17 . The method of  claim 1 , wherein the twisted yarn has approximately 20 to 30 twists per inch. 
     
     
         18 . The method of  claim 1 , wherein the organic thread and the synthetic thread are twisted together at an angle of approximately 25 to 35 degrees.