Yarn with sections having different aesthetic characteristics, articles comprising same, and methods of making said yarn and articles

Patent metadata

Field	Value
Publication number	US-12359356-B2
Application number	US-202218075771-A
Country	US
Kind code	B2
Filing date	Dec 6, 2022
Priority date	Dec 6, 2021
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

An article can comprise a backing and a plurality of yarns tufted, knitted, or woven through the backing, each yarn defining at least one aesthetic characteristic. The at least one aesthetic characteristic can comprise luster, color, size, physical attribute associated with material type, or texture. At least one yarn of the plurality of yarns can comprise an engineered yarn structure having a first yarn section and a second yarn section. The engineered yarn structure can comprise a transition junction comprises commingled portions of the first and second yarn sections. The transition junction can have a length of less than 1 millimeter. The first section can have a first type of a first aesthetic characteristic of the at least one aesthetic characteristic, and the second section can have a second type of the first aesthetic characteristic that is different from the first type.

First claim

What is claimed is:

1. An article comprising:
a backing; and
a plurality of yarns tufted, woven, or knitted through the backing, each yarn defining at least one aesthetic characteristic, wherein the at least one aesthetic characteristic comprises one or more of luster, color, size, physical attribute associated with material type, or texture,
wherein at least one yarn of the plurality of yarns comprises an engineered yarn structure having:
a first yarn section formed by a first yarn segment; and
a second yarn section formed by a second yarn segment,
wherein the engineered yarn structure comprises a transition junction that comprises commingled portions of the first yarn section and the second yarn section, wherein the transition junction has a length of less than 1 millimeter,
wherein a severed end of the first yarn segment is wrap spliced, mechanically knotted, twisted, or entangled with a severed end of the second yarn segment to form the transition junction, and
wherein the first section has a first type of a first aesthetic characteristic of the at least one aesthetic characteristic, and wherein the second section has a second type of the first aesthetic characteristic that is different from the first type.

2. The article of claim 1 , wherein the first aesthetic characteristic is color, wherein the first type is a first color, and wherein the second type is a second color.

3. The article of claim 1 , wherein the first aesthetic characteristic is luster, wherein the first type is a first luster, and wherein the second type is a second luster.

4. The article of claim 1 , wherein the first aesthetic characteristic is uniform along each of the first yarn section and the second yarn section.

5. The article of claim 1 , wherein the first yarn section of a first yarn of the at least one yarn of the plurality of yarns has a first length, wherein the first yarn section of a second yarn of the at least one yarn of the plurality of yarns has a second length that is different from the first length.

6. The article of claim 5 , wherein the article has a first axis along which rows of tufts of the first and second yarns extend, wherein the first section of each of the first and second yarns has a respective starting location along the first axis, and wherein the starting location of the first section of the first yarn is axially offset from the starting location of the first section of the second yarn along the first axis.

7. The article of claim 1 , wherein a first yarn of the at least one yarn of the plurality of yarns comprises a third yarn section, wherein the engineered yarn structure comprises a second transition junction that comprises commingled portions of the second yarn section and the third yarn section, wherein the first and third yarn sections of the first yarn both have the first type of the first aesthetic characteristic.

8. The article of claim 1 , wherein at least a first yarn of the at least one yarn of the plurality of yarns comprises sequential yarn sections that are joined at respective transition junctions and that alternate between the first and second type of the first aesthetic characteristic.

9. The article of claim 1 , wherein at least a first yarn of the at least one yarn of the plurality of yarns comprises a third yarn section formed by a third yarn segment, wherein the engineered yarn structure comprises a second transition junction that comprises commingled portions of the second yarn section and the third yarn section, wherein a second severed end of the second yarn segment is wrap spliced, mechanically knotted, twisted, or entangled with a severed end of the third yarn segment to form the second transition junction, wherein the first aesthetic characteristic of the third yarn section is a third type that is different from the first and second types.

10. The article of claim 1 , wherein each of the first yarn section and the second yarn section of each yarn of the at least one yarn of the plurality of yarns has a respective length that is randomly generated during formation of the yarns.

11. The article of claim 1 , wherein the first and second yarn sections of each yarn of the at least one yarn of the plurality of yarns have respective lengths of between 800 meters and 5000 meters.

12. The article of claim 11 , wherein the first and second yarn sections of each yarn of the at least one yarn of the plurality of yarns have respective lengths between 1000 meters and 3000 meters.

13. A method comprising:
tufting, knitting, or weaving a plurality of yarns through a backing,
wherein a first yarn of the plurality of yarns comprises an engineered yarn structure having:
a first yarn section formed by a first yarn segment; and
a second yarn section formed by a second yarn segment,
wherein the engineered yarn structure comprises a transition junction that comprises commingled portions of the first yarn section and the second yarn section, wherein the transition junction has a length of less than 1 millimeter,
wherein a severed end of the first yarn segment is wrap spliced, mechanically knotted, twisted, or entangled with a severed end of the second yarn segment to form the transition junction,
wherein the first yarn section has a first type of a first aesthetic characteristic selected from luster, color, size, or texture, and wherein the second yarn section has a second type of the first aesthetic characteristic that is different from the first type.

14. The method of claim 13 , wherein the transition junction is formed by air splicing.

15. The method of claim 13 , further comprising drawing the plurality of yarns from respective yarn packages, wherein a first yarn package of the respective yarn packages comprises the first yarn.

16. The method of claim 15 , further comprising forming the plurality of yarns.

17. The method of claim 13 , wherein a second yarn of the plurality of yarns comprises an engineered yarn structure having:
a first yarn section; and
a second yarn section,
wherein the engineered yarn structure comprises a transition junction that comprises commingled portions of the first yarn section and the second yarn section,
wherein tufting, knitting, or weaving the plurality of yarns through the backing comprises moving the backing along a first axis and tufting the plurality of yarns through the backing to form a plurality of rows that extend along the first axis, wherein the first yarn section of each of the first and second yarns has a respective starting location along the first axis, and wherein tufting, knitting, or weaving the plurality of yarns through the backing comprises tufting, knitting, or weaving the starting location of the first yarn section of the first yarn in a location that is axially offset from the starting location of the first yarn section of the second yarn along the first axis.

18. A method comprising:
forming a yarn having an engineered yarn structure comprising:
a first yarn section formed by a first yarn segment; and
a second yarn section formed by a second yarn segment,
wherein the engineered yarn structure comprises a transition junction that comprises commingled portions of the first yarn section and the second yarn section, wherein the transition junction has a length of less than 1 millimeter,
wherein the first section has a first type of a first aesthetic characteristic, and wherein the second section has a second type of the first aesthetic characteristic that is different from the first type,

wherein forming the yarn comprises wrap splicing, mechanical knotting, twisting,

Assignees

• Shaw Ind Group Inc

Inventors

• Cornwell Tansley
• Phillips Stephen D
• Bryant Christopher S

Classifications

• D02G3/22

  Yarns or threads characterised by constructional features {, e.g. blending, filament/fibre (piecing of yarns or threads D01H15/00)} · CPC title

• D02G3/44

  Yarns or threads characterised by the purpose for which they are designed {(protective gloves A41D19/00; protective clothing A62B17/00; ropes D07B1/02)} · CPC title

• D10B2401/20

  optical · CPC title

• D05C15/04

  Tufting · CPC title

• D02G3/34

  Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns {(carding machines for producing decorative or fancy effects in products D01G; drafting machines with varying draft according to a pre-arranged pattern D01H5/36)} · CPC title