Polymer filaments having profiled cross-section

Abstract

The present invention is directed to a multi-filament yarn formed at least in part from filaments having cross-sectional zigzag shape with a 180 degree axis of symmetry. The filaments have a denier per filament generally in the range of about 0.1 to about 4.0. Fabrics made from yarns formed with the filaments have high moisture wicking, soft hand, and a silk-like lustrous appearance.

1 . A synthetic polymer filament, comprising: 
 a cross-section that includes at least five contiguous segments in zigzag configuration, said cross-section having a nominal width, a nominal length and a nominal thickness.    
     
     
         2 . The synthetic polymer filament of  claim 1 , wherein adjacent segments form an angle between about 40 degrees and about 60 degrees.  
     
     
         3 . The synthetic polymer filament of  claim 1 , wherein the synthetic polymer filament comprises a polyamide synthetic polymer selected from the group consisting of: polyhexamethylene adipamide; polycaproamide; polyenanthamide; nylon 10; polydodecanolactam; polytetramethylene adipamide; polyhexamethylene sebacamide homopolymer; a polyamide of n-dodecanedioic acid and hexamethylenediamine homopolymer; and a polyamide of dodecamethylenediamine and n-dodecanedioic acid.  
     
     
         4 . The synthetic polymer filament of  claim 1 , wherein a ratio of the nominal width to the nominal thickness is less than about 3.  
     
     
         5 . The synthetic polymer filament of  claim 1  having a denier per filament between about 0.1 and about 4.0.  
     
     
         6 . The synthetic polymer filament of  claim 1 , having an indentation to thickness ratio between about 0.25 and 0.6.  
     
     
         7 . A yarn formed at least in part from the synthetic polymer filament of  claim 1 .  
     
     
         8 . The yarn of  claim 7 , wherein the yarn is formed from a number of filaments and the synthetic polymer filament of  claim 1  comprises at least about 50% of the number of filaments in said yarn.  
     
     
         9 . The yarn of  claim 7  having a denier of between about 15 and about 200.  
     
     
         10 . A fabric formed at least in part from the yarn of  claim 7 .  
     
     
         11 . A garment formed at least in part of the fabric of  claim 10 .  
     
     
         12 . A fabric formed at least in part from the synthetic polymer filament of  claim 1 .  
     
     
         13 . The fabric of  claim 12 , wherein said fabric is a double sided fabric comprising the synthetic polymer filament of  claim 1  on one side of the fabric.  
     
     
         14 . The fabric of  claim 13 , wherein a wetting agent is applied to the one side.  
     
     
         15 . The fabric of  claim 14 , wherein said wetting agent is selected from the group consisting of a hydrophilic polyamide, hydrophilic silicone, and hydrophilic polyester.  
     
     
         16 . A synthetic polymer filament, comprising: 
 a cross-section that includes five contiguous segments in zigzag configuration, wherein each segment defines a proximal end and a distal end, wherein a distal end of a first segment is connected to a proximal end of a second segment, wherein a distal end of the second segment is connected to a proximal end of a third segment, wherein a distal end of the third segment is connected to a proximal end of a fourth segment, wherein a distal end of the fourth segment is connected to a proximal end of a fifth segment, and wherein a pivot point is defined along the fourth segment and the cross-section of the filament is symmetrical when rotated 180 degrees about said pivot point.    
     
     
         17 . The synthetic polymer filament of  claim 16 , wherein adjacent segments form an angle between about 40 degrees and about 60 degrees.  
     
     
         18 . The synthetic polymer filament of  claim 16 , wherein the synthetic polymer filament comprises a polyamide synthetic polymer selected from the group consisting of: polyhexamethylene adipamide; polycaproamide; polyenanthamide; nylon 10; polydodecanolactam; polytetramethylene adipamide; polyhexamethylene sebacamide homopolymer; a polyamide of n-dodecanedioic acid and hexamethylenediamine homopolymer; and a polyamide of dodecamethylenediamine and n-dodecanedioic acid.  
     
     
         19 . The synthetic polymer filament of  claim 16  having a denier per filament of about 1.0 to about 4.0.  
     
     
         20 . The synthetic polymer filament of  claim 16  having an indentation-to-thickness ratio between about 0.25 and about 0.6.  
     
     
         21 . A yarn formed at least in part from the synthetic polymer filament of  claim 16 .  
     
     
         22 . The yarn of  claim 21 , wherein the yarn is formed from a number of filaments and the synthetic polymer filament of  claim 16  comprises at least about 50% of the total number of filaments in said yarn.  
     
     
         23 . The yarn of  claim 20  having a denier of between about 16 and about 200.  
     
     
         24 . Fabric formed at least in part from the yarn of  claim 21 .  
     
     
         25 . Garment formed from at least in part from the fabric of  claim 24 .  
     
     
         26 . The fabric of  claim 24 , wherein said fabric is a double sided fabric comprising the synthetic polymer filament of  claim 16  on one side of the fabric.  
     
     
         27 . The fabric of  claim 26 , wherein a wetting agent is applied to the one side.  
     
     
         28 . The fabric of  claim 26 , wherein said wetting agent is selected from the group consisting of a hydrophilic polyamide, hydrophilic silicone, and hydrophilic polyester.  
     
     
         29 . A synthetic polymer filament, comprising: 
 a cross-section having multiple segments arranged in a five-legged zigzagged shape including an upright W-shaped portion with an additional leg added to the W shape.