U.S. patent application number 10/305136 was filed with the patent office on 2003-11-20 for method for manufacturing elastic ultrathin filament textured yarn and the elastic ultrathin filament textured yarn manufactured from the same.
This patent application is currently assigned to Nan Ya Plastic Corp.. Invention is credited to Jen, Zo-Chun.
Application Number | 20030213224 10/305136 |
Document ID | / |
Family ID | 29417974 |
Filed Date | 2003-11-20 |
United States Patent
Application |
20030213224 |
Kind Code |
A1 |
Jen, Zo-Chun |
November 20, 2003 |
Method for manufacturing elastic ultrathin filament textured yarn
and the elastic ultrathin filament textured yarn manufactured from
the same
Abstract
This invention discloses a method for manufacturing ultra-thin
fiber yarn having elastic characteristics. Ultra-thin fiber
Textured Yarn and thermoplastic fiber are concurrently fed into a
compression air jet system to produce elastic ultra-thin fibers.
The two materials are made into a novel yarn with elastic function
using the process of this invention, which is simpler as compared
with other traditional processes associated with manufacturing
elastic complex yarn. The process of this invention is capable of
manufacturing elastic complex yarns with excellent size stability,
capable of being easily woven, suitable for the textile and
slopwork industries, and capable of producing textiles with good
elasticity and high degree of comfort.
Inventors: |
Jen, Zo-Chun; (Taipei,
TW) |
Correspondence
Address: |
EUGENE MAR, ESQ.
BACON & THOMAS, PLLC
625 SLATERS LANE
4TH FLOOR
ALEXANDRIA
VA
22314-1176
US
|
Assignee: |
Nan Ya Plastic Corp.
|
Family ID: |
29417974 |
Appl. No.: |
10/305136 |
Filed: |
November 27, 2002 |
Current U.S.
Class: |
57/333 ;
57/289 |
Current CPC
Class: |
D02G 3/328 20130101;
D02G 1/0266 20130101 |
Class at
Publication: |
57/333 ;
57/289 |
International
Class: |
D02G 001/16 |
Foreign Application Data
Date |
Code |
Application Number |
May 17, 2002 |
TW |
91110432 |
Claims
What is claimed is:
1) A method for manufacturing elastic ultra-thin fiber yarn
comprising the steps of: (a) heating, false twisting, and spinning
continuous long fiber using spinning methods to produce ultra-thin
fiber Textured Yarn; (b) spinning two thermoplastic polymers with
different shrinkage into thermoplastic fiber with elastic function
using proportioned compound spinneret; (c) Concurrently feeding
in-process ultra-thin fiber Textured Yarn and in-process
thermoplastic fiber with self-winding elastic characteristics into
a compression air jet system to form the elastic ultra-thin fiber
yarn; (d) Feeding the processed elastic ultra-thin fiber yarn
through wire feed roller; and (e) Wrapping said elastic ultra-thin
fiber yarn with winding roller.
2) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 1, wherein the spinning method used to spin said
continuous long fiber is traditional spinning.
3) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 1, wherein the spinning method used to spin said
continuous long fiber is compound spinning.
4) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 2, wherein said ultra-thin Textured Yarn and
said thermoplastic fiber with self-winding elastic characteristics
are concurrently fed into a compression air jet system and
compounded into said elastic ultra-thin fiber yarn.
5) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 4, wherein said elastic ultra-thin fiber is fed
with a false twisting processing machine into a yarn guide end.
6) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 5, wherein said elastic ultra-thin fiber yarn is
compressed and compounded with high pressure gas supplied form an
air nozzle.
7) The method for manufacturing elastic ultra-thin fiber according
to claim 6, wherein said continuous long fiber is false twisted and
processed into ultra-thin fiber Textured Yarn with filament size
below 0.5 denier.
8) The method for manufacturing elastic ultra-thin fiber according
to claim 7, further comprising application of high in-process
temperature to generate shrinkage difference within the
thermoplastic fiber and to induce elasticity.
9) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 3, wherein said ultra-thin Textured Yarn and
said thermoplastic fiber with self-winding elastic characteristics
are concurrently fed into a compression air jet system and
compounded into said elastic ultra-thin fiber yarn.
10) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 9, wherein said elastic ultra-thin fiber is fed
with a false twisting processing machine into a yarn guide end.
11) The method for manufacturing elastic ultra-thin fiber yarn
according to claim 10, wherein said elastic ultra-thin fiber yarn
is compressed and compounded with high pressure gas supplied form
an air nozzle.
12) The method for manufacturing elastic ultra-thin fiber according
to claim 11, wherein said continuous long fiber is false twisted
and processed into ultra-thin fiber Textured Yarn with filament
size below 0.5 denier.
13) The method for manufacturing elastic ultra-thin fiber according
to claim 12, further comprising application of high in-process
temperature to generate shrinkage difference within the
thermoplastic fiber and to induce elasticity.
Description
[0001] This invention relates to a novel ultra-thin fiber Textured
Yarn with elastic characteristics and its manufacturing method.
Specifically, this invention relates to a novel elastic ultra-thin
fiber Textured Yarn manufactured by concurrently feeding spun
ultra-thin fiber Textured Yarn and spun thermoplastic fiber into a
compression air jet system and passing the resulting product
through wire feed and winding rollers.
[0002] Republic of China's Patent No. 127812 entitled "the
manufacturing method of iso-shrinkage ultra-thin fiber Textured
Yarn" teaches a traditional method for manufacturing ultra-thin
fiber. Ultra-thin fiber Textured Yarn with boiling water shrinkage
below 10% and high shrinkage low crimpled gray yarn with boiling
water shrinkage above 15% are compounded and processed to form a
single yarn unit. Fabrics manufactured using yarns made with such a
traditional method have thick feel and noticeable stiffness, which
are appreciated by visual examination of the draped fabrics.
However, these fabrics lack elasticity and are not comfortable when
worn.
[0003] In response to thick feel, stiffness and lack of comfort
associated with fabrics produced using traditional methods such as
the method discussed above, and in order to produce yarn with
elastic covering characteristics, manufacturers often wrap the
produced yarn around a Spandex (trade name for a type of
polyurethane elasticity silk) periphery to form a single/dual
wrapped yarn. Additionally, the produced yarn is knobbed with high
speed air and wrapped around the periphery of a LYCRA Spandex to
produce elastic covering yarn. Although such Spandex-based yarns
have elasticity, production of the latter involve complex
manufacturing procedures and high manufacturing cost. The following
shortcomings are clear noticeable:
[0004] 1. Higher manufacturing cost due to technical complexity
associated with raw materials.
[0005] 2. Higher manufacturing cost due to technical complexity
associated with the manufacturing process.
[0006] 3. Process not applicable to high temperature dyeing and
finishing; and easy coloring embrittlement results due to moist
heat intolerance.
[0007] 4. Alkali (NaOH) intolerant decrement processing.
[0008] 5. Uneasy tension control exist during the opening of band
yarn and during finish processing, which is caused by unwanted
elasticity and reduced product quality; and industrial processing
efficiency is negatively influenced due to extreme process
difficulties.
[0009] It is an object of this invention to solve the shortcomings
associated with Spandex-based yarns production and other
traditional methods of producing yarns with elastic covering
characteristics.
[0010] Another object of this invention is to produce high-class
yarn with elastic function by false twisting thermoplastic fiber
with self-winding elasticity characteristics into ultra-thin fiber
via a compression air jet system.
[0011] Still another object of this invention is to simplify the
process of manufacturing elastic complex yarns and to reduce the
cost associated with producing elastic complex yarns. Still
further, another object of this invention is to manufacture elastic
complex yarns with excellent size stability, capable of being
easily woven, suitable for the textile and slopwork industries, and
capable of producing textiles with good elasticity and high degree
of comfort.
SUMMARY OF THE INVENTION
[0012] This invention discloses a method for manufacturing novel
ultra-thin fiber Textured Yarn with elastic characteristics. The
process involves blending ultra-thin fiber Textured Yarn with
thermoplastic fiber having self-winding characteristics.
[0013] The ultra-thin fiber Textured Yarn of this invention is
manufactured by heating, false twisting and spinning of continuous
long fiber using traditional or compound spinning methods. The
thermoplastic plastic of this invention is manufactured by spinning
two thermoplastic polymers with different shrinkage. The ultra
fiber Textured Yarn and the thermoplastic fiber are concurrently
fed into a compression air jet and compounded into the elastic
ultra-thin fiber yarn of this invention. Finally, the produced
elastic ultra-thin fiber processing yarn is fed through wire feed
rollers and subsequently wrapped with winding rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1: Shows a compound false-twist processing flow sheet
for manufacturing elastic ultra-thin fiber processing yarn. The
equipment symbols associated with the flow sheet are as follows:
(1) Silk guide; (2) First wire; (3) Heater; (4) Cooling plate; (5)
Friction ingot group; (6) Silk guide; (7) Second wire feed roller;
(8) Compression air jet system; (9) Third wire feed roller; (10)
Elastic ultra-thin fiber processing yarn; and (11) Batch
roller.
[0015] FIG. 2: Shows a self-winding elastic thermoplastic fiber
used for manufacturing the elastic ultra-thin fiber yarn of this
invention. The figure shows the configuration of two thermoplastic
polymers of different shrinkages into a fiber cross section
constituting both polymers.
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention discloses novel Ultra-thin Fiber Textured
Yarn with elastic characteristics and its manufacturing method.
Specifically, this invention relates to novel elastic ultra-thin
fiber Textured Yarn manufactured by concurrently feeding spun
ultra-thin fiber Textured Yarn and spun thermoplastic fiber into a
compression air jet system and passing the resulting product
through wire feed and winding rollers.
[0017] The ultra-thin fiber Textured Yarn of this invention is
obtained by heating, false twisting, and post processing of
continuous long fiber woven with general-synthetic fiber by using
traditional spinning or compound spinning methods to produce a yarn
whose filament size is below 0.5 denier. The traditional spinning
method, which usually occurs after a false twisting process, uses a
single polymer under traditional conditions and with traditional
equipment to spin out continuous long fiber yarn whose filament
size is below 0.5 denier. The continuous long fiber yarn is
subsequently false twisted and processed into Ultra-thin fiber
Textured Yarn whose filament size is below 0.5 denier. In contrast,
the compound spinning method, which usually occurs after a false
twisting process, uses two different polymers under traditional
conditions and with traditional equipment to spin out continuous
long fiber yarn whose filament size is below 0.5 denier. The
continuous long fiber yarn is subsequently false twisted and
processed into Ultra-thin fiber Textured Yarn whose filament size
is below 0.5 denier.
[0018] The second material used to manufacture the invention of
this patent application is thermoplastic fiber with self-winding
elastic characteristics. The thermoplastic fiber is obtained by
configuring two thermoplastic polymers of different shrinkages into
a fiber cross section by spinning with a compound spinneret having
the desired proportionality. The different contraction stresses
between the interfaces of the two thermoplastic polymers with
different shrinkages form spring-like screw and generate
self-winding elasticity. See the manufacturing diagram shown in
FIG. 2.
[0019] To form the ultra-thin fiber Textured Yarn with elastic
characteristics of this invention, thermoplastic fiber with
self-winding elastic characteristics and continuous long fiber are
first individually spun using traditional spinning methods or
compound spinning methods. Specifically, the continuous fiber is
false twisted, spun, heated, subsequently false twisted and post
processed into a ultra-thin fiber Textured Yarn whose filament size
is below 0.5 denier. The ultra-thin fiber Textured Yarn produced
from the continuous long fiber and the thermoplastic fiber is
compounded to form an in-process Textured Yarn. The in-process Yarn
is passed through a weaving process, a dyeing process and a
finishing process. The high in-process temperature is utilized to
generate shrinkage difference within the thermoplastic fiber
thereby inducing elastic characteristics in the final product.
[0020] The manufacturing process steps of this invention are
summarize as follows: ultra-thin fiber Textured Yarn is
manufactured by heating, false twisting and spinning of continuous
long fiber using traditional or compound spinning methods;
separately, thermoplastic fiber with self-winding characteristics
is manufactured by spinning two thermoplastic polymers with
different shrinkage after first being melted and spun using a
compound spinneret of desired proportion; the ultra fiber Textured
Yarn and the thermoplastic fiber are concurrently fed into a
compression air jet are compounded into elastic ultra-thin fiber
processing yarn; and the resulting elastic ultra-thin fiber
processing yarn is passed through wire feed rollers and wrapped
with winding rollers.
[0021] Referring to FIG. 1 for additional clarification of the
manufacturing process steps of this invention, ultra-thin fiber
spinning cake (A) is relaxed via silk guide (1), and passed through
a first wire feed roller (2). The resulting ultra-thin fiber
product is heated with a heater (3), passed over a cooling plate
(4) and through a friction ingot group (5). The ultra-thin fiber
product is then passed through a second wire feed roller (7) to
form the Textured Yarn. Steps 1-7 are the heating, extending, curl
reshaping and cooling processes required to produce the ultra-thin
Textured Yarn material of this invention.
[0022] Still referring to FIG. 1 of the inventive process, at the
moment the ultra Textured Yarn is fed through the second wire
rollers (7), self-winding thermoplastic fiber (B) is incorporated
into the ultra Textured Yarn through the silk guide (6), and
combined with the Textured Yarn and fed into a compression air jet
system (8) with air nozzle supplied with a considerable amount of
pressure. The ultra-thin Textured Yarn and the thermoplastic fiber
are compounded into an elastic ultra-thin fiber processing yarn
(10) and guided by a third wire feed roller (9) down stream.
Finally, the elastic yarn with feed rate controlled by the third
feed roller (9) and the winding roller (11) is produced.
[0023] Still referring to FIG. 1 of this invention, the friction
ingot group (5) is not restricted to any one type or any one
combination. All well-known ingot groups such as friction disc,
friction belt, and pin ingot, etc. are applicable. The air nozzle
of the compression air jet system (8) is not restricted to any one
type or any one combination. All well-known nozzles, such as
ordinary nozzle and mixed fiber nozzle etc. are applicable. To
achieve the maximum integration of the thermoplastic fiber into the
ultra-thin Textured Yarn to form a compound (elastic ultra-thin
fiber) with good reliability, the number of processed yarn shall be
over 85 sections/m.
[0024] The elastic ultra-thin fiber processing yarn (10) of this
invention can be woven into cloths and textiles of various shapes.
Due to the elastic effect demonstrated prior to hot water treatment
no problem of pull control exists; therefore, various shapes can be
obtained through knitter, shuttle and shuttle less loom. The
weaving and quality characteristics of this invention are superior
to contemporaneous elastic yarn complexes. By manufacturing the
elastic yarn with thermoplastic polymers interface having two
different shrinkage, which forms spring-like screw due to the
difference in shrinkage stress when exposed to high temperature
during post processing, textiles produced using this invention
demonstrated excellent elasticity and a high degree of comfort.
[0025] By way of examples of exploitation/comparison and
explanation, the evaluation method, the manufacturing processes,
conditions and process components, though not limited to the
exploitations, of the present invention may be as follows:
[0026] Explanation of Elasticity Evaluation Method
[0027] Workbench: INSTRON--6021 universal tensile testing
machine
[0028] Method:
[0029] a. Tailor 2.5 cm.times.30 cm test piece under the condition
of room temperature without tension (Containing clamping section 10
cm).
[0030] b. Test rate for 1.667 mm/Sec Return speed for 10.0
mm/Sec
[0031] c. Test piece pre-load 12 g
[0032] d. Fixed pull of 1000 g
Calculation: elastic extension (fixed pull 1000
g)=(A2-A1).div.A1.times.10- 0%
[0033] A1: Test piece length before stretching
[0034] A2: Test piece length applying fixed pull 1000 g
[0035] (Example of Exploitation)
[0036] 360d/48f polyester, an upgraded polyester compound,
ultra-thin fiber spinning cake (A) is relaxed via silk guide (1),
and passed through a first wire feed roller (2) The ultra-thin
fiber product is heated to 160.degree. C. with a heater (3) (having
a temperature range between 100-200.degree. C.). The resulting
product is passed over a cooling plate (4), false twisted by
passage through a friction ingot group (5) and extended to 2.28
times with the second wire feed roller (7) (having an extension
multiple of between 1.3-4.0), to form the Textured Yarn. At the
moment the ultra-thin Textured Yarn is fed through the second wire
roller (7), 75d/24f spun polyester, self-winding elastic fiber (B)
is incorporated into the second wire feed roller (7) via silk guide
(6) at speed of 500 m/minute (the second wire feed roller speed
range is between 300-900 m/minute). The resulting product is
combined with the Textured Yarn and fed into the air jet
compression system (8) with air nozzle having air pressure of about
50 kg/m.sup.2, at the guiding end of the yarn. The ultra-thin
Textured Yarn and the thermoplastic fiber are compounded into an
elastic ultra-thin fiber processing yarn (10) and guided by a third
wire feed roller (9) down stream.
[0037] A 225d/72d elastic ultra-thin elastic yarn with feed rate
controlled by the third feed roller (9) and the winding roller (11)
is produced consistent with the process flow chart shown in FIG. 1.
The processed yarn is used as filling, wrapped with 75d/36f
Textured Yarn, weaved and reduced by 25%. Post processing such as
burring, dyeing to produce cloth of enhanced thickness, drape, wax,
particularity, peach skin feeling and elastic extension (fixed pull
1000 g) that reaches 23.1% were performed. Clothing produced using
this exploitation maintained a high degree of comfort when
worn.
EXAMPLE OF COMPARISON
[0038] In this example, conditions are similar to the processing
conditions above. However, the self-winding elastic thermoplastic
fiber (B) is replaced with 45% high shrinkage low crimpled gray
yarn having boiling water shrinkage and dimensions of 75d/36f to
produce 225d/84f iso-shrinkage ultra-thin fiber Textured Yarn.
Similar to the above exploitation, the processed yarn is used as
filling, wrapped, weaved and reduced. Post processing such as
burring, dyeing to produce cloth of enhanced thickness, drape, wax,
particularity, peach skin feeling and elastic extension (fixed pull
1000 g) that reaches only 5.8% were performed. Thus, clothing
produced using this example possessed many shortcomings and lack
the needed comfort when worn.
[0039] Comparing the example of exploitation with the example of
comparison, it is clear that the use of properly processed
thermoplastic fiber with self-winding elastic performance and
ultra-thin fiber Textured Yarn resulted in the production of unique
elastic ultra-thin fiber with enhanced intrinsic performance, as
compared with traditional ultra-thin fiber Textured Yarn.
* * * * *