Method of producing yarns and fabrics

Abstract

The yarns of the present invention satisfy the need for a multi-purpose yarn, capable of improved abrasion resistance, seam slippage and dimensional stability while eliminating traditional fabric's backing materials and costs associated with the production thereof. In one aspect, the method of producing yarn and fabrics comprises supplying a first yarn, supplying a low melt yarn, placing the two yarns adjacent to one another, and winding the two adjacent yarns. In another aspect, the method of producing yarns and fabrics further comprises weaving the yarns into a fabric and heating the fabric, wherein heating the fabric heats the low melt yarn, melting at least one filament and adhering the low melt yarn to the first yarn or fabric. In yet another aspect, the method of producing yarns and fabrics further comprises weaving the yarns into a fabric, breaking at least one filament of the low melt yarn, and heating the low melt yarn, wherein heating the low melt yarn melts at least one broken filament thereby adhering the low melt yarn to the first yarn or fabric.

1 . A method of producing fusion yarn and fabric, comprising: 
 supplying a first yarn;    supplying a low melt yarn;    placing the first yarn adjacent to the low melt yarn; and    winding the two adjacent yarns together to create a fusion yarn.    
   
   
       2 . The method of  claim 1 , wherein the fusion yarn is textured fusion yarn.  
   
   
       3 . The method of  claim 2 , further comprising: 
 fiber spinning the first yarn;    false twist texturing the first yarn;    fiber spinning the low melt yarn; and    coupling the two yarns with an air jet covering device to create a fusion yarn.    
   
   
       4 . The method of  claim 2 , further comprising: 
 fiber spinning the first yarn;    false twist texturing the first yarn;    fiber spinning the low melt yarn; and    intermingling the two yarns with an intermingling device to create a fusion yarn.    
   
   
       5 . The method of  claim 3  or  4 , wherein the first yarn is LOY undrawn yarn.  
   
   
       6 . The method of  claim 3  or  4 , further comprising texturing the two yarns.  
   
   
       7 . The method of  claim 1 , wherein the fusion yarn is Taslan fusion yarn.  
   
   
       8 . The method of  claim 7 , further comprising: 
 feeding the first yarn as effect into an air jet device; and    feeding the low melt yarn as core and in parallel with the first yarn into an air jet device.    
   
   
       9 . The method of  claim 8 , wherein the first yarn is continuous filament yarn.  
   
   
       10 . The method of  claim 1 , wherein the fusion yarn is Chenille fusion yarn.  
   
   
       11 . The method of  claim 10 , further comprising: 
 feeding at least one first yarn as effect into a cutting and ensambling device;    feeding at least one second yarn as core in parallel with at least one first yarn and into a cutting and ensambling device, wherein at least one second yarn includes at least one low melt yarn;    twisting, trapping and cutting the yarns in the cutting and ensambling device to create fusion yarns; and    winding the fusion yarns.    
   
   
       12 . The method of  claim 11 , further comprising: 
 heat setting the fusion yarns to activate the low melt fibers.    
   
   
       13 . The method of  claim 1 , wherein the fusion yarn is novelty fusion yarn.  
   
   
       14 . The method of  claim 13 , further comprising: 
 feeding the first yarn as effect into a twister device;    feeding a second yarn into a twister device;    feeding the low melt yarn plus the first yarn as a binder, into a twister device;    coupling, twisting or effect-making the yarns in the twister device to create fusion yarns; and    winding the fusion yarns.    
   
   
       15 . The method of  claim 14 , further comprising: 
 heat setting the fusion yarns to activate the low melt fibers.    
   
   
       16 . The method of  claim 14 , wherein the first yarn is a continuous filament.  
   
   
       17 . The method of  claim 14 , wherein the first yarn is a staple tow.  
   
   
       18 . The method of  claim 14 , wherein the binder is a continuous filament.  
   
   
       19 . The method of  claim 1 , further comprising: 
 weaving the fusion yarn into a fabric; and    heating the low melt yarn, wherein heating the low melt yarn melts at least one filament of the low melt yarn.    
   
   
       20 . The method of  claim 19 , further comprising: 
 breaking at least one filament of the low melt yarn.    
   
   
       21 . The method of  claim 19  or  20 , wherein the weaving the fusion yarn into a fabric comprises: 
 warping a portion of the fusion yarn;    sending a portion of the fusion yarn to the loom; and    looming the fusion yarn into fabric.    
   
   
       22 . A composition of yarn, comprising: 
 a first yarn; and    a low melt yarn, wherein the first yarn is adjacent to the low melt yarn, and wherein the two yarns are wound together to create a fusion yarn.    
   
   
       23 . A composition of fabric, comprising: 
 a first yarn;    a low melt yarn; wherein the first yarn is adjacent to the low melt yarn, and wherein the two yarns are wound together to create a fusion yarn; and    a weave of the fusion yarn into a fabric, wherein the fabric is heated to melt at least one filament of the low melt yarn.