Woven Fabric With Bulky Continuous Filaments Yarns and Related Manufacturing Methods

Abstract

A woven fabric with continuous filament, high bulk yarns on the fabric first side is disclosed, and related method and apparatus of manufacturing same.

What is claimed: 
     
         1 . A yarn comprising:
 a plurality of continuous filaments forming a high bulk continuous filament yarn assembly, the high bulk continuous filament yarn assembly having a thickness between about 0.5 mm to about 5.0 mm for a count of between about 20 denier to about 250 denier,   wherein the high bulk continuous filament yarn has a plurality of entanglements disposed along a length that is perpendicular to the thickness.   
     
     
         2 . The yarn of  claim 1 , wherein the high bulk textured continuous filament yarn assembly has a bulk ratio between 1.1 and 3.0. 
     
     
         3 . The yarn of  claim 1 , wherein the high bulk textured continuous filament yarn assembly has between 100 to about 250 filaments per yarn assembly. 
     
     
         4 . The yarn of  claim 1 , wherein the high bulk textured continuous filament yarn is a dope-dyed or solution dyed yarn. 
     
     
         5 . The yarn of  claim 4 , wherein coloring agents are within a morphology of the filaments that form the high bulk textured continuous filament yarn assembly. 
     
     
         6 . The yarn of  claim 1 , wherein the high bulk textured continuous filament yarn is a polyethylene terephthalate filament yarn. 
     
     
         7 . A method for manufacturing a yarn, the method comprising the steps of:
 extruding a plurality of continuous filaments into a continuous filament yarn;   twisting the continuous filament yarn to form a twisted continuous filament yarn;   thermally treating the twisted continuous filament yarn to at least partially heat set the twisted continuous filament yarn to form a heat-set twisted continuous filament yarn;   after thermally treating, intermingling the plurality of continuous filaments to form a high bulk textured continuous filament yarn; and   winding the high bulk continuous filament yarn onto a yarn package.   
     
     
         8 . The method of  claim 7 , wherein the high bulk continuous filament yarn has a thickness between about 0.5 mm to about 5.0 mm for a count of between about 20 denier to about 250 denier. 
     
     
         9 . The method of  claim 7 , wherein the high bulk textured continuous filament yarn assembly has a bulk ratio between 1.1 and 3.0. 
     
     
         10 . The method of  claim 7 , wherein the high bulk textured continuous filament yarn is a dope-dyed or solution dyed yarn. 
     
     
         11 . The method of  claim 7 , wherein the high bulk textured continuous filament yarn is a polyethylene terephthalate filament yarn.