U.S. patent application number 15/083973 was filed with the patent office on 2017-07-20 for highly absorbent, super-soft and functionalized composite yarn, textile and related manufacturing method.
The applicant listed for this patent is Hongwei DUAN. Invention is credited to Hongwei DUAN.
Application Number | 20170204540 15/083973 |
Document ID | / |
Family ID | 59314390 |
Filed Date | 2017-07-20 |
United States Patent
Application |
20170204540 |
Kind Code |
A1 |
DUAN; Hongwei |
July 20, 2017 |
HIGHLY ABSORBENT, SUPER-SOFT AND FUNCTIONALIZED COMPOSITE YARN,
TEXTILE AND RELATED MANUFACTURING METHOD
Abstract
A highly absorbent, super-soft composite yarn includes a core
formed of microfibers and a covering layer formed of natural fibers
which are twisted and surround the microfibers. The microfiber is a
composite fiber having two or more components. In one structure,
the two components are held together in an interleaved structure
resembling an orange in cross-section. In another structure, the
microfibers have undergone a splitting process and the two
components are separated from each other, where the single
filaments of the two components have a linear mass density below
0.55 dtex. The natural fibers of the covering layer cotton fibers,
hemp fibers, wool fibers, bamboo fibers, silk fibers, or soybean
fibers. The microfibers are functionalized with one or more
additives, such as antibacterial, aromatic, and UV-blocking
additives. A method for manufacturing the composite yarn and
related textile is also described.
Inventors: |
DUAN; Hongwei; (Shandong,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DUAN; Hongwei |
Shandong |
|
CN |
|
|
Family ID: |
59314390 |
Appl. No.: |
15/083973 |
Filed: |
March 29, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2401/02 20130101;
D03D 15/0061 20130101; D10B 2331/02 20130101; D10B 2509/026
20130101; D10B 2211/02 20130101; D03D 1/0017 20130101; D10B 2201/02
20130101; D03D 1/007 20130101; D10B 2501/00 20130101; D01D 5/30
20130101; D10B 2331/04 20130101; D01F 8/14 20130101; D02G 3/36
20130101; D10B 2401/13 20130101; D01F 8/12 20130101; D10B 2201/10
20130101; D10B 2211/04 20130101 |
International
Class: |
D02G 3/44 20060101
D02G003/44; D03D 1/00 20060101 D03D001/00; D03D 15/00 20060101
D03D015/00; D02G 3/38 20060101 D02G003/38; D02G 3/02 20060101
D02G003/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 20, 2016 |
CN |
201610038246.7 |
Jan 20, 2016 |
CN |
201610038249.0 |
Jan 20, 2016 |
CN |
201620055579.6 |
Claims
1. (canceled)
2. A composite yarn comprising: a core formed of microfibers,
wherein each microfiber has two components which are different
materials, the two components being held together in an interleaved
arrangement in a cross-sectional view; and a covering layer formed
of natural fibers which are twisted and surround and cover the
core.
3. The composite yarn of claim 2, wherein the two components are
polyamide 6 and polyester.
4. The composite yarn of claim 3, wherein either the polyamide 6
component or the polyester component or both are functionalized
with a functional material.
5. The composite yarn of claim 4, wherein the functional material
is selected from a group consisting of antibacterial materials,
aromatic materials, and UV-blocking materials.
6. The composite yarn of claim 21, wherein the microfibers are
separate filaments of polyamide 6 and polyester which have a linear
mass density of less than or equal to 0.55 dtex.
7. The composite yarn of claim 6, wherein either the polyamide 6
filaments or the polyester filaments or both are functionalized
with the functional material.
8. The composite yarn of claim 21, wherein the functional material
is selected from a group consisting of antibacterial materials,
aromatic materials, and UV-blocking materials.
9. The composite yarn of claim 2, wherein the natural fibers of the
covering layer are selected from a group consisting of cotton
fibers, hemp fibers, wool fibers, bamboo fibers, silk fibers, and
soybean fibers.
10. A fabric made of the composite yarn of claim 2.
11.-20. (canceled)
21. A composite yarn comprising: a core formed of microfibers,
wherein at least some of the microfibers are functionalized with a
functional material; and a covering layer formed of natural fibers
which are twisted and surround and cover the core.
22. The composite yarn of claim 21, wherein the at least some of
the microfibers contain the functional material melted therein.
23. The composite yarn of claim 21, wherein the natural fibers of
the covering layer are selected from a group consisting of cotton
fibers, hemp fibers, wool fibers, bamboo fibers, silk fibers, and
soybean fibers.
24. A fabric made of the composite yarn of claim 21.
25. A composite yarn comprising: a core formed of microfibers which
include separate filaments of polyamide 6 and filaments of
polyester, the filaments having a linear mass density of less than
or equal to 0.55 dtex, wherein either the polyamide 6 filaments or
the polyester filaments or both are functionalized with a
functional material selected from a group consisting of
antibacterial materials, aromatic materials, and UV-blocking
materials; and a covering layer formed of natural fibers which are
twisted and surround and cover the core.
26. The composite yarn of claim 25, wherein either the polyamide 6
or the polyester or both contains the functional material melted
therein.
27. The composite yarn of claim 25, wherein the natural fibers of
the covering layer are selected from a group consisting of cotton
fibers, hemp fibers, wool fibers, bamboo fibers, silk fibers, and
soybean fibers.
28. A fabric made of the composite yarn of claim 25.
Description
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] This invention relates to super-fine functionalized yarns,
and in particular, it relates to highly absorbent, super-soft,
functionalized composite yarns, textile made from the yarn, and
related manufacturing methods.
[0003] Description of Related Art
[0004] Natural fibers are preferred fabric materials for garments
and other products such as towels, because they are soft to the
touch, comfortable and safe to use on the skin. But due to various
inherent limitations, the absorbance, quick-drying properties and
softness of such textile are not ideal. For example towels made of
cotton do no try quickly, and tend to become hard and less
absorbent after a period of use. Although various properties of
such fabrics can be improved by using certain functional additives
to treatment the fabrics, the desirable properties are often lost
after repeated washing, and some additives may irritate the skin.
Also, with the increased living standards, more and more demands
are placed on useful functions of fabrics, such as antibacterial
properties, UV-blocking properties, cool or warm feel to the touch,
etc.
[0005] Composite yarns typically use a high strength, high
elasticity, long synthetic fiber as the core, which is covered with
relatively short fibers such as cotton, wool, viscose fiber etc.
and form into a yarn. Composite yarn combines the desirable
properties of the long filament of the core and the outer short
fibers. One commonly known composite yarns is polyester-cotton
composite yarn, which is formed of polyester fiber as the core and
covered with cotton fibers. Another commonly known composite yarn
is spandex composite yarns, which are formed of spandex fibers as
the core and covered with other fibers. Textile and clothing made
of spandex composite yarns have desired elasticity and can stretch,
making it comfortable to wear. The main advantages of composite
yarns are the improved properties over single fiber yarns.
SUMMARY
[0006] Although the known composite yarns combine the advantages of
cotton and synthetic fibers, certain shortcomings remain. While
textile made of natural fibers feels soft, are comfortable and safe
to use, their absorbance, quick-drying properties and strengths are
weak. When natural fibers form composite yarns with polyesters and
polyamides, although the strength of the yarns is improved, they
still do not have desired absorbance, quick-drying property and
sufficiently soft feel.
[0007] Accordingly, the present invention is directed to a
composite yarn, textile made of the yarn, and related manufacturing
method that substantially obviate one or more of the problems due
to limitations and disadvantages of the related art.
[0008] An object of the present invention is to provide a composite
yarn and fabrics made of such yarn, that are highly absorbent,
quick-drying, super-soft, have a natural feel and are
functionalized. Such yarn and fabrics combine the desirable
properties of natural fibers and synthetic fibers, and have
UV-blocking, antibacterial and other desirable properties.
Moreover, such desirable properties are long-lasting.
[0009] Another object of the present invention is to provide
various products such as clothes for garment, towels, etc. that
have desirable properties such as high absorbance, quick-drying,
soft, comfortable, antibacterial, odor prevention, aromatic,
etc.
[0010] Another object of the present invention is to provide
manufacturing methods for the above composite yarn and fabrics.
[0011] Additional features and advantages of the invention will be
set forth in the descriptions that follow and in part will be
apparent from the description, or may be learned by practice of the
invention. The objectives and other advantages of the invention
will be realized and attained by the structure particularly pointed
out in the written description and claims thereof as well as the
appended drawings.
[0012] To achieve these and/or other objects, as embodied and
broadly described, the present invention provides a composite yarn
which includes: a core formed of microfibers which have two or more
components; and a covering layer formed of natural fibers which are
twisted and surround the core.
[0013] In one embodiment, each microfiber has two components held
together in an interleaved arrangement in a cross-sectional
view.
[0014] In one embodiment, the two components are polyamide 6 and
polyester.
[0015] In one embodiment, either the polyamide 6 component or the
polyester component or both are functionalized with a functional
material.
[0016] In one embodiment, the functional material is selected from
a group consisting of antibacterial materials, aromatic materials,
and UV-blocking materials.
[0017] In one embodiment, the microfibers are separate filaments of
polyamide 6 and polyester which have a linear mass density of less
than or equal to 0.55 dtex.
[0018] In one embodiment, either the polyamide 6 filaments or the
polyester filaments or both are functionalized with a functional
material.
[0019] In one embodiment, the functional material is selected from
a group consisting of antibacterial materials, aromatic materials,
and UV-blocking materials.
[0020] In one embodiment, the natural fibers of the covering layer
are selected from a group consisting of cotton fibers, hemp fibers,
wool fibers, bamboo fibers, silk fibers, and soybean fibers.
[0021] In another aspect, the present invention provides a fabric
made of the composite yarn described above.
[0022] In another aspect, the present invention provides a method
of making a fabric, which includes: forming microfibers, each
microfiber having two components held together in an interleaved
arrangement in a cross-sectional view; covering a core containing
the microfibers with a covering layer of natural fibers to form a
composite yarn; forming a grey fabric by weaving the composite
yarn; and treating the grey fabric with a causticization process to
cause the two components of the microfibers of the core to separate
from each other to form separate filaments, wherein the filaments
have a linear mass density of less than or equal to 0.55 dtex.
[0023] In one embodiment, the causticization process uses a
solution with an alkaline concentration is about 4-8 g/L at a
temperature of 100-130.degree. C.
[0024] In one embodiment, the step of forming the microfibers
includes: melting polyamide 6 (PA6) granules in a screw extruder at
a temperature of 255-270.degree. C. and a pressure of 9-10 MPa;
melting polyethylene terephthalate (PET) granules in another screw
extruder at a temperature of 280-288.degree. C. and a pressure of
9-10 MPa; feeding the melted PA6 and PET to a spinning manifold and
co-spinning them at a temperature of 140-250 MPa and a spinning
speed of 2800-3200 m/min, to form a microfiber structure having PA6
and PET components held together in an interleaved arrangement in a
cross-sectional view; and pulling the microfibers and cooling them,
wherein the cooling is by air cooling with an air speed of 0.3 to
-0.5 m/min, a relative humidity of 70-80% and a temperature of
18-23.degree. C.
[0025] In one embodiment, a weight ratio of the PET and PA6
granules is 50-85: 50-15.
[0026] In one embodiment, the step of melting the PA6 granules
includes adding a functional masterbatch to the PA6 granules, an
amount of the functional masterbatch being 1-4 wt % of the PA6
granules, and/or the step of melting the PET granules includes
adding a functional masterbatch to the PET granules, an amount of
the functional masterbatch being 1-4 wt % of the PET granules.
[0027] In one embodiment, the functional masterbatch is selected
from a group consisting of antibacterial materials, aromatic
materials, and UV-blocking materials.
[0028] In one embodiment, the natural fibers of the covering layer
are selected from a group consisting of cotton fibers, hemp fibers,
wool fibers, bamboo fibers, silk fibers, and soybean fibers.
[0029] In one embodiment, in the covering step, a tension in the
microfibers is greater than a tension in the natural fibers.
[0030] In one embodiment, the method further includes dyeing and
drying the fabric after the causticization process.
[0031] In one embodiment, the grey fabric is a towel, which
includes a ground fabric and terry which are both formed of the
composite yarn. In another embodiment, the grey fabric is used for
home textiles such as bedding sheets, covers, duvets, etc.
[0032] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 schematically illustrates the cross-section of a
composite yarn according to a first embodiment of the present
invention.
[0034] FIG. 2 schematically illustrates the cross-section of the
microfiber of the core of the composite yarn in the first
embodiment.
[0035] FIG. 3 schematically illustrates the cross-section of a
composite yarn according to a second embodiment of the present
invention.
[0036] FIG. 4 schematically illustrates the cross-section of the
microfiber of the core of the composite yarn in the second
embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] Embodiments of the present invention are described with
reference to the drawings. It should be understood that these
embodiments are used to illustrate the invention, and the invention
is not limited to the embodiments. Those skilled in the art will
appreciate that various modification and variations can be made in
the composite yarn and its manufacturing method of the present
invention without departing from the spirit or scope of the
invention. Thus, it is intended that the present invention cover
modifications and variations that come within the scope of the
appended claims and their equivalents.
[0038] As shown in FIGS. 1-4, the highly absorbent, super-soft
composite yarn includes a core 2 and a covering layer 3. The core
is formed of one or more microfibers 1, and the covering layer 3 is
formed of natural fibers which are twisted and surround the
microfibers 1. The microfiber 1 is formed from a composite fiber
having two or more components.
[0039] The natural fibers of the covering layer 3 are preferably
selected from cotton fibers, hemp fibers, wool fibers, bamboo
fibers, silk fibers and soybean fibers, or combinations
thereof.
[0040] In some embodiments, the composite yarn is a functionalized
composite yarn, where the microfibers are functionalized with one
or more additives, such as antibacterial, aromatic, and UV-blocking
additives.
[0041] In a first embodiment of the invention, shown in FIGS. 1 and
2, the microfiber 1 is formed of two components, which are
polyester and polyamide 6 in one particular implementation, the two
components being held together in an interleaved arrangement that
resembles an orange in the cross-section, as shown in FIG. 2.
[0042] FIG. 2 shows the cross-section of one microfiber 1, where
the two components 4 and 5 are interleaved in the manner as
illustrated, i.e., the two components 4 and 5 together form a
structure which has a round cross-sectional shape where the
component resemble sections of an orange. In this example, the
component 5 is polyamide 6 and the component 4 is polyester.
[0043] In a second embodiment of the invention, shown in FIGS. 3
and 4, the core 2 of the yarn is formed of microfibers 1 having the
structure shown in FIG. 2, but it has undergone a process of
splitting treatment, so that the two components 4 and 5 of the
microfibers 1 are separated from each other, as shown in FIG. 4,
where each piece of the separated component forms a fine filament
with spaces 6 between the filaments.
[0044] In FIG. 3, the core 2 is depicted as containing filaments of
the separated components, rather than the microfibers 1 where the
two components are held together in the orange-shaped structure
shown in FIGS. 1 and 2. Preferably, after the splitting process,
the single filaments in the core 2 have a linear mass density of
less than or equal to 0.55 dtex. The fine spaces 6 between the
filaments can create a capillary effect, so fabric products made of
the resulting yarn have superior absorbing properties and
quick-drying properties. The fabric products also are soft to the
touch because of the natural fiber covering 3.
[0045] In embodiments of the present invention, the fiber splitting
treatment is a causticization process (also referred to as alkali
deweighting treatment), which is performed after the yarn in the
form shown in FIGS. 1 and 2 are made (e.g. woven) into a
fabric.
[0046] In the microfiber 1, either the component 5 (e.g. polyamide
6) or the component 4 (e.g. polyester) or both may be
functionalized, i.e., made to contain one or more functional
components. The functional components may be antibacterial
materials, aromatic materials, UV-blocking materials, etc. The
resulting microfibers are referred to as functionalized
microfiber.
[0047] The composite yarn according to embodiments of the present
invention not only combines the advantages of natural fibers and
synthetic fibers, but also has superior absorbance and quick-drying
properties due to the use of microfibers. It is soft, and can be
made to have antibacterial, flame retardant, aromatic and/or
UV-blocking properties.
[0048] A composite yarn and fabric described above may be
manufactured as follows. The microfiber 1 is formed by melting PA6
(polyamide 6, or Nylon 6) and PET (polyethylene terephthalate, a
material in the polyester family) granules, and co-spinning them to
form a composite fiber structure having a cross-section that
resembles an orange as described earlier (see FIG. 2). Functional
masterbatchs are optionally added to the PA6 and/or PET granules.
The functional masterbatchs may include one or more of
antibacterial masterbatch, aromatic masterbatch, UV-blocking
masterbatch, etc.
[0049] In one example, the natural fiber 3 is bamboo fiber, and
antibacterial masterbatch is added to the PET granules.
[0050] In another example, the natural fiber 3 is cotton fiber, and
aromatic masterbatch is added to the PA6 granules. In this example,
the amount of the aromatic masterbatch is about 2.0 wt % of the
total granules, and the weight ratio of the PET and PA6 granules is
about 70:30.
[0051] More specifically, a manufacturing process according to
embodiments of the present invention included the following
steps.
[0052] (1) The PA6 and PET granules are separately dried. One or
more types of functional masterbatchs, such as antibacterial
masterbatch, aromatic masterbatch, UV-blocking masterbatch, etc.,
are dried in a separately drying tower, where the drying
temperature is about 100-120.degree. C. and the drying time is
about 8-10 hours.
[0053] (2) The dried PA6 and PET granules are separately fed into
two screw extruders to be melted. The functional masterbatch is
accurately measured with a dosing pump, and fed together with one
or both of the PA6 granules and the PET granules into the
respective screw extruders, and melted together with the PA6 and/or
PET. The melting temperature applied to the PA6 granules is about
255-270.degree. C., and the melting temperature applied to the PET
granules is about 280-288.degree. C. The pressure of the screw
extruders is about 9-10 MPa.
[0054] (3) The two melted materials are respectively measured with
melt dosing pumps and then fed to a spinning manifold, and co-spun
using an orange-shape type spinning pack to form the microfibers
having the structure shown in FIG. 2. The pressure of the melt
materials in the spinning pack is about 140-250 MPa. The spinning
speed is about 2800-3200 m/min.
[0055] (4) The spun fibers are then pulled and cooled to obtain the
functionalized microfibers. Cooling is done by air cooling, where
the air speed is about 0.3 to -0.5 m/min; the relative humidity of
the air is about 70-80% and the temperature is about 18-23.degree.
C.
[0056] Preferably, the amount of the functional masterbatch is
about 1-4 wt % of the total granules, and the weight ratio of the
PET granules and PA6 granules is about 50-85: 50-15.
[0057] The process may further include steps for making highly
absorbent, quick-drying, super soft, natural feeling fabrics, which
include the following steps.
[0058] (5) Using the functionalized microfibers as the core, and
using natural fibers as covering fibers, the core is covered with
natural fibers to form the composite yarn. When forming the cover,
the tension in the core fibers is greater than the tension in the
covering fibers.
[0059] (6) The composite yarn is woven into a grey fabric. To make
towels, the composite yarn is woven to form the ground fabric and
the terry of the grey fabric for the towels.
[0060] (7) The grey fabric is treated with an alkaline reduction
treatment (causticization), dyed, and dried to obtain the highly
absorbent, quick-drying, super-soft and natural-feeling
functionalized fabric. The temperature of the solution for the
alkaline reduction treatment is about 100-130.degree. C. and the
alkaline concentration is about 4-8 g/L. During the alkaline
reduction treatment before dyeing, the microfibers undergo
splitting, i.e. the two components of the microfibers 1 (see FIGS.
1 and 2) are separated from each other to form the structure
described earlier (see FIGS. 3 and 4). As a result, spaces are
formed between the separated filaments to improve capillary effect
of the fabric.
[0061] Preferably, in the above process, the natural fiber is
selected from cotton fibers, wool fibers, hemp fibers, silk fibers,
soybean fibers and bamboo fibers.
[0062] Preferably, in the covering step (5) described above, low
hardness, high elasticity rubber rollers are used to improve the
covering effect. Press bar clamp and collector are used to ensure
that the core is located at optimum positions.
[0063] In the process examples described below, specific values of
various process parameters are given.
Process Example 1
[0064] (1) The PA6 and PET granules are separately dried. The
antibacterial masterbatch is dried in a separately drying tower,
where the drying temperature is about 108.degree. C. and the drying
time is about 10 hours.
[0065] (2) The dried PA6 granules are fed into a screw extruder to
be melted. The antibacterial masterbatch is accurately measured
with a dosing pump, and fed together with dried PET granules into
another screw extruder to be melted. The melting temperature
applied for the PA6 granules is about 260.degree. C., and the
melting temperature applied for the antibacterial masterbatch and
PET granules is about 285.degree. C. The pressure of the screw
extruders is 9.5 MPa. The amount of the antibacterial masterbatch
is about 1.5 wt % of the total granules, and the weight ratio of
the PET granules and PA6 granules is 50:50.
[0066] (3) The two melted materials are respectively measured with
melt dosing pumps and then fed to a spinning manifold, and co-spun
using an orange-shape type spinning pack to form the microfibers.
The pressure of the melt material in the spinning pack is about 180
MPa. The spinning speed is about 3000 m/min.
[0067] (4) The spun fibers are then pulled and cooled to obtain the
functionalized microfibers. Cooling is done by air cooling, where
the air speed is about 0.35 m/min; the relative humidity of the air
is about 72% and the temperature is about 20.degree. C.
[0068] (5) The microfiber obtained above is used as the core and
covered with soybean fibers to form the composite yarn, and the
yarn is woven into a highly absorbent, quick-drying, super-soft,
and natural-feeling fabric.
Process Example 2
[0069] (1) The PA6 and PET granules are separately dried. The
aromatic masterbatch is dried in a separately drying tower, where
the drying temperature is about 115.degree. C. and the drying time
is about 9 hours.
[0070] (2) The dried PA6 and PET granules are separately fed into
two screw extruders to be melted. The aromatic masterbatch is
accurately measured with a dosing pump, and respectively fed
together with the PA6 granules and the PET granules into the screw
extruders. The melting temperature applied for the PA6 granules is
about 265.degree. C., and the melting temperature applied for the
PET granules is about 286.degree. C. The pressure of the screw
extruders is about 10 MPa. The weight ratio of the PET granules and
PA6 granules is about 60:40; the amount of the aromatic masterbatch
is about 2 wt % of the total granules and divided for the PET
granules and PA6 granules according to their weight ratio.
[0071] (3) The two melted materials are respectively measured with
melt dosing pumps and then fed to a spinning manifold, and co-spun
using an orange-shape type spinning pack to form the microfibers.
The pressure of the melt material in the spinning pack is about 220
MPa. The spinning speed is about 3100 m/min.
[0072] (4) The spun fibers are then pulled and cooled to obtain the
functionalized microfibers. Cooling is done by air cooling, where
the air speed is about 0.35 m/min; the relative humidity of the air
is about 76% and the temperature is about 22.degree. C.
[0073] (5) The microfiber obtained above is used as the core and
covered with soybean fibers to form the composite yarn, and the
yarn is woven into a highly absorbent, quick-drying, super-soft,
and natural-feeling fabric.
Process Example 3
[0074] (1) The functionalized microfiber obtained in Process
Example 1, step (4) is used as the core, and covered with cotton
fibers to form the composite yarn. When forming the cover, the
tension in the core fibers is greater than the tension in the
covering fibers. Low hardness, high elasticity rubber rollers are
used in the covering step to improve the covering effect. Press bar
clamp and collector are used to ensure that the core is located at
optimum positions.
[0075] (2) The composite yarn is woven into a grey fabric. To make
towels, the composite yarn is woven to form the ground fabric and
the terry of the grey fabric of the towel.
[0076] (3) The grey fabric is dyed, dried, and sewed to obtain the
highly absorbent, quick-drying, super-soft and natural-feeling
functionalized fabric. Before the dyeing process, the grey fabric
undergoes an alkaline reduction treatment (causticization). The
temperature for the alkaline reduction treatment is about
105.degree. C. and the alkaline concentration is about 6.5 g/L.
Process Example 4
[0077] (1) The PA6 and PET granules are separately dried. The
antibacterial masterbatch is dried in a separately drying tower,
where the drying temperature is about 112.degree. C. and the drying
time is about 9.5 hours.
[0078] (2) The dried PA6 granules are fed into a screw extruder to
be melted. The antibacterial masterbatch is accurately measured
with a dosing pump, and fed together with dried PET granules into
another screw extruder to be melted. The melting temperature
applied for the PA6 granules is about 262.degree. C., and the
melting temperature applied for the antibacterial masterbatch and
PET granules is about 288.degree. C. The pressure of the screw
extruders is about 9 MPa. The amount of the antibacterial
masterbatch is about 2 wt % of the total granules, and the weight
ratio of the PET granules and PA6 granules is about 70:30.
[0079] (3) The two melted materials are respectively measured with
a melt dosing pump and then fed to a spinning manifold, and co-spun
using an orange-shape type spinning pack to form the microfibers.
The pressure of the melt material in the spinning pack is about 215
MPa. The spinning speed is about 3050 m/min.
[0080] (4) The spun fibers are then pulled and cooled to obtain the
functionalized microfibers. Cooling is done by air cooling, where
the air speed is about 0.45 m/min; the relative humidity of the air
is about 75% and the temperature is about 22.degree. C.
[0081] (5) The microfiber obtained above is used as the core and
covered with soybean fibers to form the composite yarn. When
forming the cover, the tension in the core fibers is greater than
the tension in the covering fibers. Low hardness, high elasticity
rubber rollers are used in the covering step to improve the
covering effect. Press bar clamp and collector are used to ensure
that the core is located at optimum positions.
[0082] (6) The composite yarn is woven into a grey fabric. The grey
fabric may be a flat fabric or towel. To make towels, the composite
yarn is woven to form the ground fabric and the terry of the grey
fabric of the towel.
[0083] (7) The grey fabric is dyed, dried, and sewed to obtain the
highly absorbent, quick-drying, super soft and natural-feel
functionalized fabric. Before the dyeing process, the grey fabric
undergoes an alkaline reduction treatment (causticization). The
temperature for the alkaline reduction treatment is about
115.degree. C. and the alkaline concentration is about 5.5 g/L.
[0084] In another process example, the amount of the antibacterial
masterbatch is about 3 wt % of the total granules, and the weight
ratio of the PET granules and PA6 granules is about 55:45.
[0085] Properties of some fabric products made using the above
exemplary manufacturing processes are summarized in the table
below:
TABLE-US-00001 TABLE 1 absorption Absorbing Product ratio speed
antibacterial effect Process 374% 3 s Staphylococcus aureus Example
1 (MRSA) > 99.9%; E. coli > 99.9 Process 395% 3 s Example 2
Process 390% 3 s Staphylococcus aureus Example 3 (MRSA) > 99.9%;
E. coli > 99.9 Process 384% 3 s Example 4
[0086] Properties of some towel products made using the above
exemplary manufacturing processes are summarized in the table
below:
TABLE-US-00002 TABLE 2 absorption Absorbing Product ratio speed
antibacterial effect Process 740% 4 s Staphylococcus aureus Example
3 (MRSA) > 99.9% (Towel) Process 725% 4 s Staphylococcus aureus
Example 4 (MRSA) > 99.9% (Towel)
[0087] The composite yarns and fabrics made from such yarns have
the desirable properties of both polyester fibers and polyamide
fibers. Moreover, because after the splitting process the linear
mass density of the filaments of the microfiber core is less than
or equal to 0.55 dtex, the fabric is super soft and has high
absorbance due to capillary effect; there absorbance can be as high
as 4 to 5 times that of similar cotton products. Meanwhile, because
of the natural fibers that form the cover layer, the fabrics have
the soft feel of natural fibers, and are comfortable to wear.
Further, the functional materials added in the microfiber core give
the fabrics special properties such as antibacterial, UV-blocking
and aromatic properties. Cloths made of such fabrics are safe for
skin contact and can also prevent bacterial growth and undesirable
odor generated by bacterial growth.
[0088] It will be apparent to those skilled in the art that various
modification and variations can be made in the composite yarns,
textile and related manufacturing methods of the present invention
without departing from the spirit or scope of the invention. Thus,
it is intended that the present invention cover modifications and
variations that come within the scope of the appended claims and
their equivalents.
* * * * *