Low-Density Yarn Products and Methods of Making Same

Abstract

Disclosed are low-density yarn products, articles of manufacture that include such yarn products and methods of making such yarn products. The yarn products may be used for insulation, as for example in apparel or other articles, including building structures or any other application requiring temperature control. The yarn products may be a twisted yarn product that can include a core yarn and a low-density overfeed yarn of large loops protruding from the core and a binder yarn twisted around the core to hold the low-density overfeed yarn of large loops in place on the core yarn.

That which is claimed is: 
     
         1 . A yarn product comprising a plurality pieces of a low-density yarn formulated as a three-dimensional matrix, and wherein the low-density yarn comprises a base yarn and an effect yarn. 
     
     
         2 . The yarn product of  claim 1 , wherein the base yarn and/or the effect yarn comprises polyethylene, polypropylene and/or polyester. 
     
     
         3 . The yarn product of  claim 1 , wherein the low-density yarn is formulated as loops that extend substantially radially from the base yarn. 
     
     
         4 . The yarn product of  claim 1 , wherein the density is less than 30 grams per liter. 
     
     
         5 . A twisted yarn product comprising a low-density yarn and a core yarn, wherein the low-density yarn is formulated as loops that extend substantially radially from the core yarn. 
     
     
         6 . The twisted yarn product of  claim 5 , further comprising a binder yarn, wherein the binder yarn is twisted around the core yarn and the low-density yarn to hold the low-density yarn in position relative to the core yarn. 
     
     
         7 . The twisted yarn product of  claim 5 , formulated as a three-dimensional matrix. 
     
     
         8 . The twisted yarn product of  claim 5 , wherein the low-density yarn comprises a base yarn and an effect yarn. 
     
     
         9 . The twisted yarn product of  claim 8 , wherein the low-density base yarn and/or the effect yarn comprises polyethylene, polypropylene and/or polyester. 
     
     
         10 . The twisted yarn product of  claim 8 , wherein the low-density effect yarn is formulated as loops that extend substantially radially from the base yarn. 
     
     
         11 . The twisted yarn product of  claim 5 , wherein the low-density yarn is an overfeed yarn. 
     
     
         12 . The twisted yarn product of  claim 5 , wherein the core yarn comprises a base yarn and an effect yarn. 
     
     
         13 . The twisted yarn product of  claim 6 , wherein the binder yarn comprises a core yarn and an optional effect yarn. 
     
     
         14 . The twisted yarn product of  claim 5 , wherein the density is less than 24 grams per liter. 
     
     
         15 . An article of manufacture comprising a plurality pieces of a low-density yarn formulated as a three dimensional matrix. 
     
     
         16 . The article of manufacture of  claim 15 , wherein the plurality pieces of a low-density yarn formulated as a three dimensional matrix used comprise a density of less than 30 grams per liter. 
     
     
         17 . An article of manufacture comprising:
 (a) a core yarn;   (b) a low-density yarn, wherein the low-density yarn is formulated as loops that extend substantially radially from the core yarn; and   (c) a binder yarn, wherein the binder yarn is twisted around the core yarn and the low-density yarn to hold the low-density yarn in position relative to the core yarn.   
     
     
         18 . The article of manufacture of  claim 17 , wherein the article is formulated as a three-dimensional matrix. 
     
     
         19 . The article of manufacture of  claim 18 , wherein the density of the matrix used is less than 24 grams per liter. 
     
     
         20 . A method of making a twisted yarn product comprising a core yarn and a low-density overfeed yarn comprising the steps of:
 (a) combining a core yarn and a low density yarn; and   (b) twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn.   
     
     
         21 . The method of  claim 20 , comprising using a twister to perform the step of twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn. 
     
     
         22 . The method of  claim 20 , wherein the process used generate the low-density yarn comprises air-jet texturing. 
     
     
         23 . The method of  claim 20 , further comprising step (c) of formulating the yarn product as a three-dimensional matrix. 
     
     
         24 . The method of  claim 20 , further comprising using a twister to combine a binder yarn with the core yarn and the low-density yarn in step (a) and twisting all three of the core yarn, the low-density yarn and the binder yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis, the low-density yarn forms loops that protrude from the core yarn, and the binder yarn holds the loops in place in step (b). 
     
     
         25 . The method of  claim 20 , wherein the low-density yarn is an overfeed yarn.