Polyamide fabric enhancing body warming

Abstract

The invention provides a polyamide yarn and fabric for making clothes articles which have deodorizing effect and which enhance warming and drying on the skin of the wearer.

Claims

1. A yarn for manufacturing a fabric with warm-maintaining and deodorizing properties, the yarn consisting of: i) polyamide (PA); ii) coffee carbon powder (CC) in an amount between 0.3% and 0.8% by weight of the yarn; and iii) an inorganic additive in an amount between 0.05% and 0.5% by weight of the yarn; wherein said PA is Nylon 66, said CC originates from coffee husks, and said inorganic additive is a metal oxide (MO) selected from the group consisting of: TiO.sub.2, Al.sub.2O.sub.3, ZrO.sub.2, ZnO, SiO.sub.2, and combinations thereof, wherein said CC and said MO are homogeneously dispersed in said Nylon 66 in molten state; and wherein said fabric exhibits (a) a temperature elevation higher by at least 5° C. when compared with a reference fabric which is prepared by the same method as said fabric with warm-maintaining and deodorizing properties except for the absence of said CC and MO in a halogen lamp test employing a 500 watt halogen lamp at a distance of 50 cm from the fabric while measuring and recording the temperature increase for 600 seconds, starting from initial ambient temperature, and (b) a deodorizing rate of at least 50% in the ammonia test characterizing the relative decrease of residual ammonia concentration from initial gas ammonia concentration of 100 ppm in a closed bottle with the fabric after 24 hours.

2. A yarn according to claim 1, wherein said MO is in an amount between 0.05% and 0.25% by weight of said yarn.

3. A yarn according to claim 1, wherein said MO is at least three inorganic additives selected from TiO.sub.2, Al.sub.2O.sub.3, ZrO.sub.2, ZnO, and SiO.sub.2.

4. A fabric knitted or woven from a polyamide yarn according to claim 1, exhibiting (a) a temperature elevation higher by at least 5° C. than a reference fabric in a halogen lamp test, and (b) a deodorizing rate of at least 50% in the ammonia test.

5. A textile article comprising a fabric according to claim 4, selected from underwear, outerwear, pantyhose, panties, tights, hosiery, stockings, socks, body-wear, slacks, shirts, pants, dresses, suits, sweaters, sports-wear, and sport clothes.

6. A textile article according to claim 5, exhibiting warm-maintaining, drying, and deodorizing effects on the skin of a wearer.

7. A textile article according to claim 5, exhibiting deodorizing properties, and assisting in keeping the physiological temperature of the wearer skin and in drying said skin.

8. A process for manufacturing a textile article according to claim 5, comprising: i) providing Nylon 66; ii) providing a concentrate containing PA, CC in a concentration of from 6% to 10%, and MO in a concentration of from 3% to 5%; iii) mixing said Nylon with said concentrate, wherein the amount of said concentrate is from 3% to 9% of the mass of said Nylon; iv) spinning a yarn from the mixture obtained in step iii) thereby obtaining the coffee carbon-containing polyamide yarn; and v) knitting or weaving a fabric from the coffee carbon-containing yarn of step iv); thereby obtaining a warm-maintaining, drying, and deodorizing fabric.

9. A process for manufacturing a polyamide fabric according to claim 4, comprising i) providing Nylon 66; ii) providing a concentrate containing PA, CC in a concentration of from 6% to 10%, and MO in a concentration of from 3% to 5%; iii) mixing said Nylon with said concentrate, wherein the amount of said concentrate is from 3% to 9% of the mass of said Nylon; iv) spinning a yarn from the mixture obtained in step iii) thereby obtaining the coffee carbon-containing polyamide yarn; and v) knitting or weaving a fabric from the coffee carbon-containing yarn of step iv); thereby obtaining a warm-maintaining, drying, and deodorizing fabric.

10. A process for manufacturing a coffee carbon-containing polyamide yarn according to claim 1, comprising: i) providing Nylon 66; ii) providing a concentrate containing said PA, said CC in a concentration of from 6% to 10%, and said MO in a concentration of from 3% to 5%; iii) melting said Nylon and mixing it with said concentrate, thereby homogeneously dispersing said CC and said MO in the molten Nylon, wherein the amount of said concentrate is from 3% to 9% of the mass of said Nylon; and iv) spinning a yarn from the mixture obtained in step iii) thereby obtaining the carbon coffee-containing polyamide yarn.

11. A process according to claim 10, wherein said concentrate in step ii) contains about 8% of CC and about 4% MO, and wherein said concentrate in step iii) is admixed into said Nylon in an amount of from 4% to 8% of the mass of said Nylon.

12. A textile article obtained from the yarn of claim 1, selected from underwear, outerwear, pantyhose, panties, tights, hosiery, stockings, socks, body-wear, slacks, shirts, pants, dresses, suits, sweaters, sports-wear, and sport clothes.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) It has now been found that polyamide containing about 0.5% coffee carbon powder and about 0.2% inorganic oxides enables a surprisingly efficient protection against cold, when spun and knitted into a fabric, while also enabling good skin drying and providing deodorizing effects. It was found that the above desirable effects did not compromise other properties, like mechanical properties, of the yarn and fabric. For example, prepared was a master-batch of polyamide containing 8% coffee carbon powder made from coffee husks, and 3% oxides comprising TiO.sub.2, Al.sub.2O.sub.3, ZrO.sub.2, ZnO, or silica; molten Nylon 66 was homogenized with the master-batch concentrate which was added in various amounts; a yarn was spun, and a fabric was knitted; and a temperature rising test was run to find that the fabric according to the invention showed a temperature elevation higher by about 10° C. than the reference fabric; the reference fabric was prepared in the same way but lacked the carbon powder and oxides.

(2) The invention relates to a polyamide comprising carbon coffee powder prepared by carbonizing the shale of coffee beans. Preferably, said polyamide (PA) is PA66 or PA6, and said coffee carbon (CC) is homogeneously dispersed in molten PA in an amount of between 0.1% and 2.0%, preferably between 0.2% and 1.0%. All percentage values are in weight percents. Said polyamide with coffee carbon (PA/CC) preferably comprises metal oxides (MO) in an amount preferably between about 0.3% and 0.8%. The term MO as used herein comprises oxides of typical metals and silicon dioxide as well. Said polyamide with coffee carbon (PA/CC) may comprise metal oxides silicates, sulfates, carbonates or other minerals in an amount between about 0.1% and 0.5%. Said CC may be added to molten PA in the form of a concentrate, for example as CC dispersed in a polyamide like PA 6 or PA 66. Said oxides may be added in the form of the same concentrate, together with the CC. In a preferred embodiment, both the CC and the oxides are prepared as a master-batch, for example containing PA and CC in an amount of from 6% to 10%, and oxides in a half of that amount. A typical master-batch may comprise an MO mixture containing TiO.sub.2, SiO.sub.2 and ZrO.sub.2 in an amount of from 3% to 4%, or TiO.sub.2, ZrO.sub.2, ZnO and Al.sub.2O.sub.3 in an amount of from 3% to 4%. The polyamide comprising the coffee carbon and the oxides (PA/CC/MO) is spun into yarns, and the yarns are knitted or woven according to the desired properties of the final textile articles.

(3) The invention relates to a special yarn, to fabric comprising then yarn, and to apparel articles comprising said fabric, enabling maintaining the surface temperature of the wearer's skin at physiologically optimal values, whereas the wear articles are comfortable to touch and feel warm, and have deodorizing effects. The warming effects of the materials according to the invention are confirmed in objective laboratory tests, such as halogen lamp heating test. For example, a Nylon 66 yarn comprising about 0.6% CC and about 0.2% MO may be spun and knitted to an apparel, for example including pantyhose, socks, sport clothes, shirts, pants, sports underwear, exhibiting, in a heating test, a temperature elevation which is by 10° C. higher than achieved by a comparative apparel lacking the active additives.

(4) The invention aims at providing a special yarn for knitting or weaving a nylon fabric which feels pleasant and warm on the skin of a wearer using a wear article made of said fabric. The invention, thus, relates to a manufacturing process comprising steps of i) providing Nylon, preferably Nylon 6 or Nylon 66, containing CC and MO, said MO possibly comprising Ti, Zr, Zn, Al, Si, or their combination, ii) melt spinning said Nylon, iii) knitting or weaving a fabric to be used in making apparel, thereby obtaining an apparel maintaining the skin surface temperature and humidity, while also exhibiting deodorizing effect. Said step i) may comprise mixing said Nylon with a CC+MO concentrate, for example by adding 8% of a master-batch mixture containing 8% CC and 4% MO. Said step iii) may provide apparels such as pantyhose, tights, sweaters, and underwear, sports clothes, socks, shirts, etc. Said step i) preferably comprises incorporating carbon and inorganic additives into the polymer, wherein the particle size of the inorganic additive may be from 0.1 μm to 5 μm. The total effect of the wear article according to the invention results from the structural properties of the fabric, including physical and chemical properties of the fiber affecting its heat conductivity and its sensory effects on the skin.

(5) The articles to be made of the yarn according to the invention include, in one embodiment, underwear such as knitted leg-wear and body-wear garment, sports wear, hosiery, underwear, tights, knitwear, sweaters, slacks, suits, pantyhose, pants, shirts, socks, etc. The invention provides articles, knitted or woven of PA/CC/MO yarn, providing pleasant feeling on skin touch, supporting quick transport of the skin humidity including perspiration outside, while efficiently assisting in maintaining optimal skin temperature and in suppressing the release of the body odors to the environment by absorbing odor compounds, thus effectively having deodorizing effects; said odor compounds may be released during washing said textile article. The yarn and warming garment according to the invention, thus, help to slow down the heat transport from the body to the environment, without hindering skin drying. The ability of the fabric and articles to keep the covered surface warm, as well as the deodorizing ability, were proven in laboratory objective tests by measuring heating curves and deodorizing rates.

(6) The invention will be further described and illustrated in the following examples.

EXAMPLES

Example 1

(7) The heating properties of the fabrics were characterized by halogen lamp test in the laboratory of at Hua Mao Nano-Tech Co. Ltd using the following experimental conditions. The lamp source-detector distance was 50 cm, the lamp power was 500 watt. The heating-up time was 600 seconds. Lamp source angle was 35 degrees. The detector temperature, starting with the initial ambient temperature, was recorded and the temperature elevation was plotted against time. The temperature elevation of the fabric according to the invention was compared with the elevation of the reference fabric manufactured the same way, but without adding the master-batch components.

Example 2

(8) The deodorizing properties of the fabrics were characterized at Taiwan Textile Research Institute using the following conditions. The reference volatile material used in the test was ammonia. A deodorizing textile sample 10 cm×10 cm was placed in a quartz bottle with an initial gas ammonia concentration of 100 ppm. The residual ammonia concentration in ppm (RC) was measured after 24 hours. The deodorizing rate (DR) of a sample in % was defined as
DR=100−RC

(9) A reference sample showed zero value of DR.

Example 3

(10) The employed Nilit PA polymer had the properties shown in table 1. The employed additive master-batch, obtained from Hua Mao Nano-Tech Co. Ltd., comprised 8.4% CC, and 3.6% inorganic oxides, mainly TiO.sub.2.

(11) TABLE-US-00001 TABLE 1 Polymer properties Nilit B40 Relative viscosity RV 40.5 Amine end groups Meq/Kg 44.6 TiO.sub.2 content % 0.03 Humidity Ppm 1150

(12) Bright polyamide 66 man manufactured in NILIT was mixed with the master-batch (concentrate) above in an amount of 8.2% (according to the invention) or was used without mixing with said concentrate (reference of comparative sample). Spinning on POY pilot machine consisted mainly of extruder 3E10/24S made by BARMAG, screw diameter 38 mm. spinning beam with 4 packs to adapt 64 mm diameter spinneret and BARMAG CW 900/6 winder. The POY yarn spun to titer of 55/34 and then textured on SCRAGG DCS 1200 pilot machine to both 44/34/1 and 44/34/2. The yarns are either 1 ply (44/34/1) with twist direction S or Z, or 2 ply (44/34/2) where 2 end S and Z are combined together on the texturing machine, providing a total titer of 88 dtex and total number of filaments of 68. The spinning parameters are in Tables 2. The yarn was textured on false twist texturing machine in two modifications, as shown in Tables 3 and 4, relating to 44/34/1 and 44/34/2 respectively. Samples with carbon coffee and samples without carbon coffee are described, dyed and non dyed. Samples with the carbon coffee yield higher temperature effects.

(13) Knitted cloth samples, including coffee carbon yarn (PA/CC/MO) and reference yarn (PA), either without or with dyeing, were tested for heating properties and for deodorizing properties as explained in Examples 1 and 2. The final temperature values after 600 seconds for four cloth samples were as follows:

(14) PA/CC/MO without dyeing: 65° C.

(15) PA without dyeing: 53° C.

(16) PA/CC/MO with dyeing: 62° C.

(17) PA with dyeing: 55° C.

(18) TABLE-US-00002 TABLE 2 Spinning parameters and POY properties for the sample according to the invention and the comparative sample Coffee carbon 55/34 regular 55/34 B40 Melt temperature ° C. 284 284 Extruder outlet pressure Bar 100 100 Spinneret initial pressure Bar 150 150 Winding speed m/min 4500 4500 Titer Dtex 57.4 57.6 Elongation % 63.6 75.9 Tenacity cN/dtex 3.26 3.84

(19) TABLE-US-00003 TABLE 3 Conditions and single ply textured yarn properties 44/34/1 coffee carbon yarn 44/34/1 B40 Winding speed m/min 683 683 Draw ratio 1.286 1.286 D/Y ratio 2.14 2.14 Disk configuration 1-7-1 1-7-1 Heater temperature ° C. 215 215 Titer Dtex 45.4 45.4 Tenacity cN/dtex 3.75 3.85 Elongation % 21.1 22.6 Crimp Contraction % 45.6 44.3 Crimp Modulus % 19.6 18.3 Crimp Stability % 90.5 89.8

(20) TABLE-US-00004 TABLE 4 Conditions and 2 ply textured yarn properties 44/34/2 coffee 44/34/2 carbon yarn B40 Winding speed m/min 683 683 Draw ratio 1.286 1.286 D/Y ratio 2.14 2.14 Disk configuration 1-7-1 1-7-1 Heater temperature ° C. 215 215 Titer Dtex 91.4 92.2 Tenacity cN/dtex 3.98 3.88 Elongation % 22.8 24.2 Crimp Contraction % 40.8 41.2 Crimp Modulus % 17.3 17.9 Crimp Stability % 86.8 86.7

(21) Thus, a fabric according to the invention exhibited a temperature elevation higher by 12° C. and by 7° C., respectively, than a reference fabric, when checking two types of cloth. As for the deodorizing rate, it was measured for the sample after dyeing, and was found to be 85% for the fabric according to the invention and 0% for the reference sample.

Example 4

(22) The same PA polymer and the same additive master-batch as employed in Example 3 were used, but Bright polyamide 66 was mixed with the master-batch in an amount of 4.5% (according to the invention) or was used without the additive (comparative). The process is characterized in the following tables.

(23) TABLE-US-00005 TABLE 5 Spinning parameters and POY yarn properties for the sample according to the invention and the comparative sample Coffee carbon 55/34 regular 55/34 B40 Melt temperature ° C. 284 284 Extruder outlet pressure Bar 100 100 Spinneret initial pressure Bar 150 150 Winding speed m/min 4500 4500 Titer dtex 57.5 57.6 Elongation % 66.2 79.8 Tenacity cN/dtex 3.29 3.64

(24) TABLE-US-00006 TABLE 6 Conditions and single ply textured yarn properties 44/34/1 coffee 44/34/1 carbon yarn B40 Winding speed m/min 683 683 Draw ratio 1.286 1.286 D/Y ratio 2.14 2.14 Disk configuration 1-7-1 1-7-1 Heater temperature ° C. 215 215 Titer dtex 45.8 45.6 Tenacity cN/dtex 3.92 3.93 Elongation % 24.3 23.8 Crimp Contraction % 44.5 45.8 Crimp Modulus % 18.3 19.3 Crimp Stability % 86.7 87.9

(25) TABLE-US-00007 TABLE 7 Conditions and 2 ply textured yarn properties 44/34/2 coffee 44/34/2 carbon yarn B40 Winding speed m/min 683 683 Draw ratio 1.286 1.286 D/Y ratio 2.14 2.14 Disk configuration 1-7-1 1-7-1 Heater temperature ° C. 215 215 Titer Dtex 91.2 90.9 Tenacity cN/dtex 3.94 3.94 Elongation % 25.1 24.6 Crimp Contraction % 41.4 42.5 Crimp Modulus % 46.6 17.0 Crimp Stability % 82.9 84.3

(26) Knitted cloth samples, including coffee carbon yarn (PA/CC/MO) and reference yarn (PA), both dyed black, were tested for heating properties and for deodorizing properties as explained in Examples 1 and 2. The final temperature values after 600 seconds for four cloth samples were as follows:

(27) PA/CC/MO dyed black: 50° C.

(28) PA dyed black: 43° C.

(29) Thus, a fabric according to the invention exhibited a temperature elevation higher by 7° C. than a reference fabric.

Example 5

(30) Sleeves were knitted of fabrics as described in Example 3, comprising the coffee carbon yarn of the invention without dyeing, with dyeing, and reference yarn. The sleeves were washed in 50 cycles and their heating properties were rechecked. The values remained practically unchanged.

(31) While this invention has been described in terms of some specific examples, many modifications and variations are possible. It is therefore understood that within the scope of the appended claims, the invention may be realized otherwise than as specifically described.