Method for coating fibers and yarns and the coated products formed therefrom

Abstract

A method for coating one or more yarn components, either individually or in an assembled configuration, with a (co)polymer coating is provided involving (i) immersing the one or more yarn components, either individually or as an assembled unit of two or more of said yarn components, in a treatment bath containing a carrier medium and a (co)polymer that can be dissolved or dispersed in the carrier medium; (ii) removing the one or more yarn components from the treatment bath; and (iii) evaporating excess carrier medium from the one or more yarn components to thereby form a coating of the (co)polymer on a surface of the one or more yarn components; and the coated yarn products formed thereby.

1 . A composite yarn comprising: 
 a. two or more yarn components; and    b. a (co)polymer coating on at least one of said two or more yarn components.    
   
   
       2 . The composite yarn of  claim 1 , wherein said two or more yarn components form (i) a core comprising at least one of said two or more yarn components, and (ii) one or more wrapping layers wrapped around said core, wherein said (co)polymer coating coats at least one of (i) said core, (ii) one or more of said wrapping layers, or both.  
   
   
       3 . The composite yarn of  claim 2 , wherein said core comprises two or more yarn components, at least one of which is a high-performance fiber.  
   
   
       4 . The composite yarn of  claim 1 , wherein said two or more yarn components are blended together and said (co)polymer coating forms a coating around the resultant blended yarn.  
   
   
       5 . The composite yarn of  claim 1 , wherein said (co)polymer is at least one member selected from the group consisting of polyvinylchloride, polyurethane polymers and copolymers, and ethylene-vinyl acetate copolymers.  
   
   
       6 . The composite yarn of  claim 2 , wherein said (co)polymer is at least one member selected from the group consisting of polyvinylchloride, polyurethane polymers and copolymers, and ethylene-vinyl acetate copolymers.  
   
   
       7 . The composite yarn of  claim 2 , wherein said (co)polymer forms a coating on an exterior surface of the assembled composite yarn.  
   
   
       8 . The composite yarn of  claim 2 , wherein said (co)polymer forms a coating directly on said core.  
   
   
       9 . The composite yarn of  claim 2 , wherein said core comprises two or more yarns in an arrangement with respect to each other selected from parallel, twisted around one another or one wrapped around the other(s).  
   
   
       10 . The composite yarn of  claim 9 , wherein said (co)polymer forms a coating around at least one of said two or more yarns in said core.  
   
   
       11 . The composite yarn of  claim 2 , wherein said (co)polymer coating coats said core and at least one of said wrapping layers.  
   
   
       12 . The composite yarn of  claim 11 , wherein said (co)polymer coating coats said core and each of said wrapping layers.  
   
   
       13 . A method for coating one or more yarn components with a (co)polymer, comprising: 
 a. immersing said one or more yarn components, either individually or as an assembled unit of two or more of said yarn components, in a treatment bath comprising a carrier medium and a (co)polymer that can be dissolved or dispersed in said carrier medium;    b. removing said one or more yarn components from said treatment bath; and    c. evaporating excess carrier medium from said one or more yarn components to thereby form a coating of said (co)polymer on a surface of said one or more yarn components.    
   
   
       14 . The method of  claim 13 , wherein said carrier medium is water.  
   
   
       15 . The method of  claim 13 , wherein said (co)polymer is at least one member selected from the group consisting of polyvinylchloride, polyurethane polymers and copolymers, and ethylene-vinyl acetate copolymers.  
   
   
       16 . The method of  claim 13 , wherein said one or more yarn components are assembled to form a composite yarn prior to said immersing step.  
   
   
       17 . The method of  claim 13 , wherein said treatment bath further comprises at least one member selected from the group consisting of antimicrobial agents, antistatic agents, colorants, and lubricants.  
   
   
       18 . The method of  claim 13 , wherein said immersing step is performed by passing said one or more yarn components continuously through said treatment bath.  
   
   
       19 . The method of  claim 18 , wherein said evaporating step is performed by wrapping said one or more yarn components around a heated roller a number of revolutions sufficient to permit evaporation of substantially all of said carrier medium while in contact with said heated roller at a given continuous throughput of said one or more yarn components.  
   
   
       20 . The method of  claim 19 , further comprising a step of collecting said coated one or more yarn components on a bobbin or tube.  
   
   
       21 . The method of  claim 19 , further comprising drying said coated one or more yarn components by heating said coated one or more yarn components at a temperature sufficient to remove the remainder of said carrier medium.  
   
   
       22 . The method of  claim 21 , wherein said drying step is performed by passing said coated one or more yarn components through a heated oven at a temperature and for a duration of time sufficient to effect said drying.  
   
   
       23 . The method of  claim 19 , further comprising drying the collected coated one or more yarn components by placing the collected yarn and the tube or bobbin on which the one or more yarn components are collected into a heater at a temperature and for a duration of time sufficient to effect said drying.  
   
   
       24 . The method of  claim 13 , wherein said (co)polymer is present in said treatment bath in an amount of from 1-15% by weight.