Adhesive core chenille yarns and fabrics and materials formed therefrom

Abstract

The present invention is directed to chenille yarns, fabrics prepared therefrom, and items formed therewith. The chenille yarns comprise an adhesive component that is incorporated into the yarn is such a way that the yarns, and the fabrics made therefrom, exhibit excellent physical characteristics, particularly abrasion resistance.

1 . A chenille yarn comprising a first core yarn, a second core yarn, a plurality of effect yarn segments positionally maintained by and extending radially from the core yarns, and an adhesive polymer blend adhering at least a portion of the effect yarn segments to at least one of the first and second core yarn, 
 wherein the polymer blend is formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the polymer blend substantially wets out a surface at a flow activating temperature without requiring the application of pressure.    
   
   
       2 . The chenille yarn of  claim 1 , wherein the first molecular weight of the at least one polymer of the first blend component is sufficiently high to prevent the substantial wet out of the at least one polymer of the first blend component at the activating temperature without the application of pressure.  
   
   
       3 . The chenille yarn of  claim 2 , wherein the second molecular weight of the at least one compound of the second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to prevent processing of the at least one compound of the second blend component alone.  
   
   
       4 . The chenille yarn of  claim 1 , wherein the polymer blend substantially wets out a surface at the activating temperature without requiring the application of pressure in a time of about two minutes or less.  
   
   
       5 . The chenille yarn of  claim 1 , wherein the activating temperature is about 75° C. to about 175° C.  
   
   
       6 . The chenille yarn of  claim 1 , wherein the first blend component comprises at least one polymer having a molecular weight that is at least about three times higher than the molecular weight of the at least one compound of the second blend component.  
   
   
       7 . The chenille yarn of  claim 1 , wherein the first blend component comprises at least one polymer having a molecular weight that is at least about five times higher than the molecular weight of the at least one compound of the second blend component.  
   
   
       8 . The chenille yarn of  claim 1 , wherein the first blend component comprises at least one polymer having a first melt flow rate, and the second blend component comprises at least one compound having a second melt flow rate that is greater than the first melt flow rate.  
   
   
       9 . The chenille yarn of  claim 1 , wherein the first blend component comprises at least one polymer having a first melt flow rate, and the second blend component comprises at least one compound having a second melt flow rate that is at least about five times greater than the first melt flow rate.  
   
   
       10 . The chenille yarn of  claim 1 , wherein the polymer blend comprises at least one polymer selected from the group consisting of polyolefins, polyesters, acrylics, polyamides, elastomeric polymers, polyacrylonitrile, acetals, fluoropolymers, epoxies, phenoxies, vinyl alcohol polymers, polyesterimides, polyhydroxyl alkanoates (PHA), polysulfone, polyetheretherketone, cellulose acetate, rayons, biopolymers, polyurethanes, hot melt adhesives, copolymers thereof, terpolymers thereof, ionomers thereof, and combinations thereof.  
   
   
       11 . The chenille yarn of  claim 1 , wherein said polymer blend comprises at least one elastomeric polymer.  
   
   
       12 . The chenille yarn of  claim 1 , wherein the at least one compound of the second blend component comprises a substantially crystalline or semicrystalline polymer.  
   
   
       13 . The chenille yarn of  claim 12 , wherein the first blend component comprises at least one polymer having a glass transition temperature (Tg) and wherein the substantially crystalline or semicrystalline polymer has a melting point that is greater than the Tg of the at least one polymer of the first blend component.  
   
   
       14 . The chenille yarn of  claim 13 , wherein the at least one polymer having the glass transition temperature (Tg) is a phenoxy compound.  
   
   
       15 . The chenille yarn of  claim 14 , wherein the substantially crystalline or semicrystalline polymer is a plasticizer.  
   
   
       16 . The chenille yarn of  claim 15 , wherein the substantially crystalline or semicrystalline polymer plasticizer has a molecular weight that is less than the molecular weight of the phenoxy and has a melting point that is greater than the Tg of the phenoxy compound.  
   
   
       17 . The chenille yarn of  claim 1 , wherein at least one of the first and second blend components comprises a functionalized polymer.  
   
   
       18 . The chenille yarn of  claim 1 , wherein at least one of the first and second blend components comprises a polyolefin.  
   
   
       19 . The chenille yarn of  claim 18 , wherein both of the first and the second blend components comprise a polyolefin.  
   
   
       20 . The chenille yarn of  claim 18 , wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, polybutylene, copolymers thereof, terpolymers thereof, and combinations thereof.  
   
   
       21 . The chenille yarn of  claim 18 , wherein the polyolefin is functionalized.  
   
   
       22 . The chenille yarn of  claim 18 , wherein the polyolefin is elastomeric.  
   
   
       23 . The chenille yarn of  claim 18 , wherein the polyolefin is functionalized by reaction with at least one unsaturated anhydride, unsaturated acid or unsaturated ester.  
   
   
       24 . The chenille yarn of  claim 18 , wherein the polyolefin is modified by reaction with at least one unsaturated anhydride, unsaturated acid or unsaturated ester selected from the group consisting of maleic anhydride, citraconic anhydride, itaconic anhydride, glutaconic anhydride, 2,3-dimethylmaleic anhydride, maleic acid, fumaric acid, citraconic acid, itaconic acid, mesaconic acid, glutaconic acid, acrylic acid, methacrylic acid, crotonic acid, 2-pentenoic acid, 2-methyl-2-pentenoic acid, dimethyl malcate, diethyl maleatc, di-n-propyl malcate, diisopropyl maleate, dimethyl fumarate, diethyl fumarate, di-n-propyl fumarate, di-isopropyl maleate, dimethyl itaconate, methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl crotonate, and ethyl crotonate.  
   
   
       25 . The chenille yarn of  claim 18 , wherein the polyolefin comprises a maleic anhydride modified polyolefin.  
   
   
       26 . The chenille yarn of  claim 18 , wherein at least one of the first and second blend components comprises a maleic anhydride modified polyolefin, and the second component comprises a substantially crystalline polyolefin.  
   
   
       27 . The chenille yarn of  claim 1 , wherein the polymer blend comprises a coating on at least a portion of at least one of the core yarns.  
   
   
       28 . The chenille yarn of  claim 1 , wherein at least one of the core yarns comprises a multicomponent fiber, and wherein the polymer blend comprises at least one component of the multicomponent fiber.  
   
   
       29 . The chenille yarn of  claim 28 , wherein the multicomponent fiber comprises a core-sheath fiber, and wherein the polymer blend comprises the sheath.  
   
   
       30 . The chenille yarn of  claim 1 , wherein at least one of the core yarns comprises a material selected from the group consisting of polyamides, polyamines, polyimides, polyacrylics, polycarbonates, polydienes, polyepoxides, polyesters, polyethers, polyfluorocarbons, polyolefins, polyphenylenes, silicon containing polymers, polyurethanes, polyvinyls, polyacetals, polyarylates, and copolymers thereof, terpolymers thereof, and combinations thereof.  
   
   
       31 . A fabric comprising a chenille yarn according to  claim 1 .  
   
   
       32 . A chenille yarn comprising a first core yarn, a second core yarn, and a plurality of effect yarn segments positionally maintained by and extending radially from the core yarns, wherein at least one of the first and second core yarns comprises a continuous sheath/core filament, the sheath comprising an adhesive component.  
   
   
       33 . The chenille yarn of  claim 32 , wherein the adhesive component comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the polymer blend substantially wets out a surface at a flow activating temperature without requiring the application of pressure.  
   
   
       34 . The chenille yarn of  claim 33 , wherein the first molecular weight of the at least one polymer of the first blend component is sufficiently high to prevent the substantial wet out of the at least one polymer of the first blend component at the activating temperature without the application of pressure.  
   
   
       35 . The chenille yarn of  claim 34 , wherein the second molecular weight of the at least one compound of the second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to prevent processing of the at least one compound of the second blend component alone.  
   
   
       36 . The chenille yarn of  claim 33 , wherein the adhesive comprises a blend of a polyolefin and a paraffin wax.  
   
   
       37 . The chenille yarn of  claim 32 , wherein the adhesive comprises at least one maleic anhydride modified polymer.  
   
   
       38 . The chenille yarn of  claim 32  wherein the adhesive comprises at least one polyethylene oxide.  
   
   
       39 . The chenille yarn of  claim 32 , wherein the adhesive comprises at least one polar, thermoplastic polymer having a melting temperature of less than 200° C.  
   
   
       40 . The chenille yarn of  claim 32 , wherein the adhesive comprises a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of pressure, the polymer blend further having blocking resistance properties, the polymer blend comprising at least one polymer having a first molecular weight and a glass transition temperature (Tg), and a substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the Tg of the at least one polymer.  
   
   
       41 . The chenille yarn of  claim 32 , wherein the adhesive comprises a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of pressure, the polymer blend further having blocking resistance properties, the polymer blend comprising a phenoxy having a first molecular weight and a glass transition temperature (Tg), and a substantially crystalline plasticizer having a second molecular weight that is less than the first molecular weight of the phenoxy and having a melting point that is greater than the Tg of the phenoxy.  
   
   
       42 . The chenille yarn of  claim 32 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight, 
 wherein the first molecular weight of the at least one polymer of the first blend component is at least about three times higher than the molecular weight of the at least one compound of the second blend component, and    wherein the polymer blend substantially wets out a surface without requiring the application of pressure at a temperature in the range of about 100° C. to about 150° C.    
   
   
       43 . The chenille yarn of  claim 32 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one elastomeric polymer, and the second blend component comprising a substantially crystalline or semicrystalline polymer.  
   
   
       44 . The chenille yarn of  claim 32 , wherein the adhesive comprises metal particles.  
   
   
       45 . The chenille yarn of  claim 32 , wherein, a fabric formed using the chenille yarn exhibits an abrasion resistance measured in double strokes according to the ASTM D-4157 abrasion test of at least about 50,000 double strokes.  
   
   
       46 . A fabric comprising a chenille yarn according to  claim 32 .  
   
   
       47 . A product of manufacture comprising a fabric according to  claim 46 .  
   
   
       48 . A fabric formed using a chenille yarn, the fabric exhibiting an abrasion resistance measured in double strokes according to the ASTM D-4157 abrasion test of at least about 50,000 double strokes, wherein the chenille yarn comprises a first core yarn, a second core yarn, a plurality of effect yarn segments positionally maintained by and extending radially from the core yarns, and an adhesive component adhering at least a portion of the effect yarn segments to at least one of the first and second core yarn.  
   
   
       49 . The fabric of  claim 48 , wherein the fabric formed using the chenille yarn exhibits an abrasion resistance of at least about 60,000 double strokes.  
   
   
       50 . The fabric of  claim 48 , wherein the fabric formed using the chenille yarn exhibits an abrasion resistance of at least about 70,000 double strokes.  
   
   
       51 . The fabric of  claim 48 , wherein the fabric formed using the chenille yarn exhibits an abrasion resistance of at least about 80,000 double strokes.  
   
   
       52 . The fabric of  claim 48 , wherein the fabric formed using the chenille yarn exhibits an abrasion resistance of at least about 90,000 double strokes.  
   
   
       53 . The fabric of  claim 48 , wherein the fabric formed using the chenille yarn exhibits an abrasion resistance of at least about 100,000 double strokes.  
   
   
       54 . The fabric of  claim 48 , wherein the chenille yarn has a weight of 1250 yards/pound and the fabric has a weight of 13.5 ounces per linear yard, has 20 warp ends per inch, having 13.5 picks per inch, and has a 2 ounce per linear yard acrylic latex backing applied thereto,  
   
   
       55 . The fabric of  claim 48 , wherein the adhesive component comprises a coating on at least a portion of at least one of the core yarns.  
   
   
       56 . The fabric of  claim 48 , wherein at least one of the core yarns comprises a multicomponent fiber, and wherein the adhesive component comprises at least one component of the multicomponent fiber.  
   
   
       57 . The fabric of  claim 56 , wherein the multicomponent fiber comprises a core-sheath fiber, and wherein the adhesive component comprises the sheath.  
   
   
       58 . The fabric of  claim 48 , wherein at least one of the core yarns comprises a material selected from the group consisting of polyamides, polyamines, polyimides, polyacrylics, polycarbonates, polydienes, polyepoxides, polyesters, polyethers, polyfluorocarbons, polyolefins, polyphenylenes, silicon containing polymers, polyurethanes, polyvinyls, polyacetals, polyarylates, and copolymers thereof, terpolymers thereof, and combinations thereof.  
   
   
       59 . The fabric of  claim 48 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the polymer blend is capable of substantially wetting out a surface at a flow activating temperature without requiring the application of pressure.  
   
   
       60 . The fabric of  claim 59 , wherein the first molecular weight of the at least one polymer of the first blend component is sufficiently high to prevent the substantial wet out of the at least one polymer of the first blend component at the activating temperature without the application of pressure.  
   
   
       61 . The fabric of  claim 60 , wherein the second molecular weight of the at least one compound of the second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing of the at least one compound of the second blend component alone.  
   
   
       62 . The fabric of  claim 48 , wherein the adhesive comprises at least one maleic anhydride modified polymer.  
   
   
       63 . The fabric of  claim 48 , wherein the adhesive comprises at least one polyethylene oxide.  
   
   
       64 . The fabric of  claim 48 , wherein the adhesive comprises at least one polar, thermoplastic polymer having a melting temperature of less than 200° C.  
   
   
       65 . The fabric of  claim 48 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight, 
 wherein the first molecular weight of the at least one polymer of the first blend component is at least about three times higher than the molecular weight of the at least one compound of the second blend component, and    wherein the polymer blend substantially wets out a surface without requiring the application of pressure at a temperature in the range of about 100° C. to about 150° C.    
   
   
       66 . The fabric of  claim 48 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one elastomeric polymer, and the second blend component comprising a substantially crystalline or semicrystalline polymer.  
   
   
       67 . The fabric of  claim 48 , wherein the adhesive comprises metal particles.  
   
   
       68 . A method of preparing a pre-bonded chenille yarn comprising: 
 feeding at least two core yarns and an effect yarn into a chenille machine, wherein at least one of the core yarns comprises continuous sheath/core filament, the sheath comprising an adhesive;    entangling the at least two core yarns and the effect yarn in the chenille machine;    removing from the chenille machine a non-bonded chenille yarn having a plurality of segments of the effect yarn extending radially from the at least two core yarns of the chenille yarn;    feeding the non-bonded chenille yarn into an adhesive activation chamber; and    heating the non-bonded chenille yarn sufficiently to activate the adhesive and adhesively bond the effect yarn to the core yarns, thereby forming a pre-bonded chenille yarn.    
   
   
       69 . The method of  claim 68 , wherein the adhesion activation chamber comprises a continuous autoclave apparatus.  
   
   
       70 . The method of  claim 68 , wherein the adhesive comprises metal particles, and wherein the adhesion activation chamber comprises an apparatus generating microwave radiation.  
   
   
       71 . The method of  claim 68 , wherein the adhesive comprises a blend of a polyolefin and a paraffin wax.  
   
   
       72 . The method of  claim 68 , wherein the adhesive comprises at least one maleic anhydride modified polymer.  
   
   
       73 . The method of  claim 68  wherein the adhesive comprises at least one polyethylene oxide.  
   
   
       74 . The method of  claim 68 , wherein the adhesive comprises a polymer blend formed of a first blend component and a second blend component, the first blend component comprising at least one polymer having a first molecular weight, and the second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the polymer blend substantially wets out a surface at a flow activating temperature without requiring the application of pressure.  
   
   
       75 . The chenille yarn of  claim 74 , wherein the first molecular weight of the at least one polymer of the first blend component is sufficiently high to prevent the substantial wet out of the at least one polymer of the first blend component at the activating temperature without the application of pressure.  
   
   
       76 . The chenille yarn of  claim 75 , wherein the second molecular weight of the at least one compound of the second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to prevent processing of the at least one compound of the second blend component alone.  
   
   
       77 . A method of air jet weaving a chenille fabric comprising feeding a pre-bonded chenille yarn prepared according to  claim 68  into an air jet weaving apparatus.