Durable fabric including bulk continuous filament yarn

Abstract

An article comprising a yarn; wherein said yarn comprises: (a) a plurality of bulked continuous filaments; (b) a denier of about 200 to 2000; (c) a denier per filament of about 1 to about 20; and (d) a tenacity of about 2.0 to about 7.0 grams per denier; wherein said yarn is interlaced.

1 . An article comprising a yarn; wherein said yarn comprises:
 (a) a plurality of bulked continuous filaments;   (b) a denier of about 200 to 2000;   (c) a denier per filament of about 1 to about 20; and   (d) a tenacity of about 2.0 to about 7.0 grams per denier;   wherein said yarn is interlaced.   
     
     
         2 . The article of  claim 1 , wherein said filaments have a round cross-section. 
     
     
         3 . The article of  claim 1 , wherein said filaments have a non-round cross-section. 
     
     
         4 . The article of  claim 1 , wherein said denier per filament is about 1 to about 8. 
     
     
         5 . The article of  claim 1 , wherein said yarn comprises a polymer selected from the group consisting of polyamide, polyester, polyolefins, copolymers thereof, and combinations thereof. 
     
     
         6 . The article of  claim 5 , wherein said polymer comprises a polyamide selected from nylon 6 and nylon 6,6. 
     
     
         7 . The article of  claim 5 , wherein said polymer comprises MXD6. 
     
     
         8 . The article of  claim 5 , wherein said polymer comprises oxidized polyacrylonitrile. 
     
     
         9 . The article of  claim 1 , wherein said bulked continuous filaments comprise a polymer additive. 
     
     
         10 . The article of  claim 5 , wherein said polymer comprises solution dyed nylon. 
     
     
         11 . The article of  claim 1 , wherein said yarn has a bulk of about 1.0 to about 12.0 cm 3 /g. 
     
     
         12 . The article of  claim 1 , wherein said yarn has tenacity of about 3.0 to about 7.0 grams per denier. 
     
     
         13 . The article of  claim 1 , wherein said yarn has a tenacity of about 4.0 to about 6.0 grams per denier. 
     
     
         14 . The article of  claim 1 , wherein said yarn has a degree of interlacing of 2 to 60 nodes/meter. 
     
     
         15 . The article of  claim 1 , wherein said article is a fabric. 
     
     
         16 . The article of  claim 15 , wherein said fabric is knit or woven. 
     
     
         17 . The article of  claim 15 , wherein said fabric is coated. 
     
     
         18 . The article of  claim 15 , wherein said fabric has a grab strength of about 80 to about 1200 pounds. 
     
     
         19 . The article of  claim 15 , wherein said fabric has a tear strength of about 8 to about 150 pounds. 
     
     
         20 . The article of  claim 15 , wherein said fabric has a Taber abrasion resistance of about 80 to about 4000 cycles. 
     
     
         21 . A method comprising:
 (a) spinning a synthetic yarn;   (b) drawing said yarn;   (c) bulking said yarn in the absence of air jet texturing;   (d) interlacing said yarn; and   (e) winding said yarn onto a package.   
     
     
         22 . The method of  claim 21 , wherein said bulking is conducted by stuffer box, edge crimping or gear crimping. 
     
     
         23 . The method of  claim 21 , wherein said draw ratio is about 2.5 to about 4. 
     
     
         24 . The method of  claim 21 , wherein said drawing step provides a tenacity of about 2 to about 7 grams per denier. 
     
     
         25 . The method of  claim 21 , wherein said drawing step includes a draw roll having a surface speed of about 2500-4000 meters/min and a temperature of about 160° C. to about 210° C. 
     
     
         26 . The method of  claim 21 , wherein said steps are part of an in-line/coupled process. 
     
     
         27 . An article comprising a fabric, wherein said fabric comprises a yarn comprising:
 (a) a plurality of bulked continuous filaments;   (b) a denier of about 300 to about 2000;   (c) a denier per filament of about 1 to 8,   (d) a tenacity of about 2.0 to about 7.0 grams per denier,   wherein said yarn is interlaced.   
     
     
         28 . The article of  claim 27 , wherein said yarn has a denier of about 200 to about 1200; a denier per filament of about 2 to about 5; and a tenacity of about 4.0 to about 6.0. 
     
     
         29 . The article of  claim 27 , wherein said filaments have a round cross-section.