U.S. patent application number 15/646646 was filed with the patent office on 2018-05-31 for woven fabric with bulky continuous filaments yarns and related manufacturing methods.
The applicant listed for this patent is WELSPUN INDIA LIMITED. Invention is credited to Dipali Goenka, Subrata Palit.
Application Number | 20180148866 15/646646 |
Document ID | / |
Family ID | 57209643 |
Filed Date | 2018-05-31 |
United States Patent
Application |
20180148866 |
Kind Code |
A1 |
Goenka; Dipali ; et
al. |
May 31, 2018 |
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.
Inventors: |
Goenka; Dipali; (Mumbai,
IN) ; Palit; Subrata; (Mumbai, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WELSPUN INDIA LIMITED |
Mumbai |
|
IN |
|
|
Family ID: |
57209643 |
Appl. No.: |
15/646646 |
Filed: |
July 11, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15275278 |
Sep 23, 2016 |
9702064 |
|
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15646646 |
|
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62232769 |
Sep 25, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 3/04 20130101; D10B
2403/0114 20130101; D10B 2201/02 20130101; D10B 2503/06 20130101;
D03D 15/0077 20130101; D02G 3/36 20130101 |
International
Class: |
D02G 3/36 20060101
D02G003/36; D02G 3/04 20060101 D02G003/04; D03D 15/00 20060101
D03D015/00 |
Claims
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.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S.
application Ser. No. 15/275,278, filed Sep. 23, 2016, which claims
priority to, and the benefit of, U.S. Provisional Application No.
62/232,769, filed Sep. 25, 2015, entitled "Woven Fabric With Bulky
Continuous Filaments Yarns, Bedding Articles, And Related
Manufacturing Methods," the entire disclosures of which are
incorporated by reference into this application for all
purposes.
TECHNICAL FIELD
[0002] The present disclosure relates to a woven fabric with high
bulk continuous filaments yarns and related manufacturing
methods.
BACKGROUND
[0003] Bedding products, such as sheeting, are typically woven
fabrics made from 100% cotton fibers or cotton and synthetic fiber
blends. Synthetic fiber blends that include polyester, acrylic,
nylon, or viscose rayon fibers are also widely used for sheeting
applications. Maximizing durability, softness and other performance
features that meet consumer preferences is challenging and
unpredictable. The demand for improved bedding products is strong
which indicates a need for the right combination of product
attributes that can meet that demand.
SUMMARY
[0004] There is a need for a woven fabric that has high bulk
continuous filaments yarns disposed on one side of the fabric,
bedding articles made from same, and related manufacturing methods.
An embodiment of the present disclosure is a woven fabric
comprising a plurality of warp yarns. Each one the warp yarns is a
staple spun yarn. The fabric includes a plurality of weft yarns
interwoven with the plurality of warp yarns to define the woven
fabric. Each one of the plurality of weft yarns is a high bulk
textured continuous filament yarn. The woven fabric defies a first
side and a second side that is opposed to the first side. The
plurality of weft yarns are interwoven with the plurality of warp
yarns such that the weft yarns define a substantial majority of the
face of the woven fabric, thereby exposing high bulk textured
continuous filament yarns along a substantial majority of the
face.
[0005] Another embodiment of the present disclosure is a woven
fabric, comprising a plurality of warp yarns. Each one of the
plurality of warp yarns is a high bulk textured continuous filament
yarn. The woven fabric includes a plurality of weft yarns
interwoven with the plurality of warp yarns to define the woven
fabric. Each one the plurality of weft yarns is a staple spun yarn.
The woven fabric defines a face and a second side that is opposed
to the face. The plurality of weft yarns are interwoven with the
plurality of warp yarns such that the warp yarns define a
substantial majority of the face of the woven fabric, thereby
exposing high bulk textured continuous filament yarns along a
substantial majority of the face.
[0006] Another embodiment of the present disclosure is a woven
fabric, comprising a plurality of warp yarns and a plurality of
weft yarns interwoven with the plurality of warp yarns to define
the woven fabric. In the woven fabric, either a) an entirety of the
weft yarns are high bulk textured continuous filament yarns and the
warp yarns are staple spun yarns, or b) an entirety of the warp
yarns are high bulk textured continuous filament yarns and the weft
yarns are staple spun yarns. The woven fabric defines a face and a
second side that is opposed to the face. The plurality of weft
yarns are interwoven with the plurality of warp yarns such that the
high bulk textured continuous filament yarns define a substantial
majority of the face of the woven fabric.
[0007] Another embodiment of the present disclosure is a method of
manufacturing a woven fabric. The method includes the step of
weaving the woven fabric with a plurality of warp yarns and a
plurality of weft yarns. In the weaving step, either a) an entirety
of the weft yarns are high bulk textured continuous filament yarns
and the warp yarns are staple spun yarns, or b) an entirety of the
warp yarns are high bulk textured continuous filament yarns and the
weft yarns are staple spun yarns. The weaving step arranges the
warp and weft yarns such that the high bulk textured continuous
filament yarns define a substantial majority of a face of the woven
fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing summary, as well as the following detailed
description of illustrative embodiments of the present application,
will be better understood when read in conjunction with the
appended drawings. For the purposes of illustrating the present
application, there is shown in the drawings illustrative
embodiments of the disclosure. It should be understood, however,
that the application is not limited to the precise arrangements and
instrumentalities shown.
[0009] FIG. 1 is a plan view of a woven fabric according to an
embodiment of the present disclosure.
[0010] FIG. 2 is cross-sectional view of the woven fabric taken
along line 2-2 in FIG. 1.
[0011] FIGS. 3A and 3B are schematics of a texturizing apparatus
used to form the high bulk, textured yarn in the woven fabric shown
in FIGS. 1 and 2.
[0012] FIG. 4 is a process flow diagram for the texturizing
apparatus shown in FIG. 3A.
[0013] FIG. 5 is schematic process flow diagram for manufacturing
the bedding article including the woven fabric illustrated in FIG.
1.
[0014] FIG. 6 illustrates high bulk textured yarn used in the
fabric shown in FIGS. 1 and 2 compared to typical continuous
filament yarns for similar deniers.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0015] Turning to FIGS. 1 and 2, an embodiment of the present
disclosure is a woven fabric 10 having a plurality of warp yarns 20
and a plurality of weft yarns 40 interwoven with the plurality of
warp yarns 20 to define the woven fabric 10. In accordance with
present disclosure, either a) the weft yarns 40 are high bulk
textured continuous filament yarns and the warp yarns 20 are staple
spun yarns, or b) the warp yarns 20 are high bulk textured
continuous filament yarns and the weft yarns 40 are staple spun
yarns. The woven fabric 10 includes a face 12 and a back 14
opposite the face 12 along direction 8. The warp yarns 20 extend
along a warp or longitudinal direction 6 and the weft yarns 40
extend along a weft direction 4 (or lateral or cross direction).
The woven fabric is designed such that a substantial portion of the
face 12 includes exposed high bulk textured continuous filament
yarns and a substantial portion of the back 14 includes exposed
staple spun yarns. Furthermore, the high bulk textured filament
yarns can be dyed prior to fabric formation, e.g. dope dyed,
solution dyed, or package dyed.
[0016] The woven fabric as disclosed herein has improved
performance features over typical woven products, such as those
used as sheeting products. For instance, woven products as
described herein have stain release functionality, are bleach safe,
display good color fastness to benzoyl peroxide, salicylic acid,
retinol, and other cosmetic ingredients. The woven fabrics have
good color fastness properties in home laundering and light
fastness, and improved antistatic properties. The use of high bulk
yarns also result in a soft, bulky, fabric hand.
[0017] As described above, embodiments of the present disclosure
include bedroom articles, including, but not limited to flat
sheets, fitted sheets, pillow cases, shams, euro shams, comforters,
duvets, bed-skirt, blankets, mattress covers, and the like. One
embodiment is a coordinated bedding system comprising a plurality
of system components. The system components include a comforter, a
duvet, a bed skirt, a blanket, and two or more a flat sheet, a
fitted sheet, a pillow case, or a sham. Each system component
includes the woven fabric prepared in accordance with the present
disclosure. Furthermore, the bedding articles are manufactured such
that the high bulk, textured weft yarns define the face of the
bedding article. In alternative embodiments, the woven fabrics can
be used in garments.
[0018] The woven fabric 10 may be defined by a number of different
woven structures. Exemplary woven structures include, but are not
limited to: plain weaves; basket weaves, satins (e.g. satin dobby
base, satin stripe satin 5/1, satin 4/1 satin; 4/1 satin base
strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1 satins); rib
weaves (e.g. 2.times.1 rib weave; 2.times.2 rib weave; or 3.times.1
rib weave); twill weaves, percale, and oxford weaves. In one
example, the woven fabric is a plain weave. In another example, the
woven fabric is a satin weave. In another example, the woven fabric
is a 4/1 satin. In another example, the woven fabric is a 4/1 satin
dobby diamond weave. In another example, the woven fabric is a 4/1
satin dobby stripe. In another example, the woven fabric is a 4/1
satin jacquard weave. In one example, the plurality of warp yarns
are arranged to define a warp end density between about 50 warp
ends per inch and about 300 warp ends per inch. The weft yarns are
arranged to define a weft density between about 50 picks per inch
and about 300 picks per inch. The woven fabric design is such that
the face of the fabric is substantially comprised of high bulk,
texturized weft yarns. In some cases, the weave design is used to
present the weft yarn on the face of the fabric, e.g. satin weaves.
In other examples, the bulk of the weft yarns create the effect
that the filamentary fibers extend out from the fabric such that
the face of the fabric is predominately the weft filaments. For
example, the warp end density may be adjusted (decreased) to
increase the number of weft yarns per square inch, which can
increase the amount of bulky weft yarns extending outwardly from
the fabric face.
[0019] The woven design includes several variations, including
where: a) the weft yarns 40 are high bulk textured continuous
filament yarns and the warp yarns 20 are staple spun yarns; b) the
warp yarns 20 are high bulk textured continuous filament yarns and
the weft yarns 40 are staple spun yarns; c) the weft yarns 40 are
exclusively high bulk textured filament yarns the warp yarns do not
include any filament yarns; and d) the warp yarns 20 are
exclusively high bulk textured filament yarns and the weft yarns 40
do not include any filament yarns. Where high bulk continuous
filaments are used, the woven fabric design is selected so that the
high bulk continuous filament yarns comprise a substantial majority
of the face 12.
[0020] In an exemplary embodiment, the warp yarns 20 include staple
spun yarns and the weft yarns 40 are high bulk continuous filament
yarns. The warp and weft yarns are described below consistent with
such an embodiment for clarity of description. It should evident
that the either warp or weft yarns can comprise the high bulk
continuous filament yarns and the other of the warp and weft yarns
comprise staple spun yarns.
[0021] In accordance with the illustrated embodiment, the woven
fabrics includes staple yarns formed from natural fibers or a blend
of natural and synthetic fibers. In one example, the staple yarns
are spun, cotton fiber yarns or blended yarns. While the staple
yarn is preferably cotton, in certain alternative embodiments, the
staple yarn can include cotton fibers blended with other natural or
synthetic fibers. In such an example, the natural fibers could
include silk, linen, flax, bamboo, hemp, wool, and the like. The
synthetic fibers in this example are those fibers that result in
fabric structures with good hand, drape, and softness. Such
synthetic fibers include cellulosic fibers, including rayon fibers
(e.g. Modal, Lyocell) or thermoplastic fibers, such as polyethylene
terephthalate (PET) fiber, polylactic acid (PLA) fiber,
polypropylene (PP) fibers, polyamide fibers, and microfiber staple
fibers.
[0022] The staple yarns can be formed using a variety of staple
yarn formation systems. For instance, staple yarn formation may
include bale opening, carding, optionally combing, drafting,
roving, and yarn spinning (yarn spinning processes are not
illustrated) to the desired count and twist level. In some cases,
the staple yarns can be plied into 2-ply, 3-ply, or 4-ply
configurations. After yarn spinning, the staple yarns are wound
into the desired yarn packages for weaving. In one example, ring
spinning is the preferred spinning system. However, the staple
yarns can be formed using open end spinning systems, rotor spun
spinning systems, vortex spinning systems, core spinning yarns, jet
spinning yarns, or compact spinning systems. Furthermore, the
spinning system may include methods used form the Hygrocotton.RTM.,
disclosed in U.S. Pat. No. 8,833,075, entitled "Hygro Materials for
Use In Making Yarns And Fabrics," (the 075 patent). The 075 patent
is incorporated by reference into present disclosure. Accordingly,
the staple yarns can be ring spun yarns, open end yarns, rotor spun
yarns, vortex spun yarns, core spun yarns, jet spun yarns, or
compact spun yarns. In another embodiment, the warp yarns can be
Hygrocotton.RTM. yarns marketed by Welspun India Limited.
Furthermore, yarns can be formed as disclosed in the 075 patent.
Preferably, the staple yarn is a ring spun yarn. The staple yarn,
however, be any type of spun yarn structure.
[0023] While the yarns are described in relation to the process
used to make them, one of skill in the art will appreciate that the
each staple yarn described above has structural differences unique
to each yarn formation system. Thus, the description of the yarns
above is also a description of yarn structure. Furthermore, in
certain alternative embodiments, the warp yarns can be filament
yarns, such as when the weft yarns are staple spun yarns and the
woven fabric design is such that a substantial portion of the face
12 is exposed warp yarns
[0024] The staple yarns have a range of counts for the yarn types
and fibers as described above. For instance, the staple yarn can
have count in a range between about 30 Ne (177 denier) to about 80
Ne (66.4 denier). In one example, the staple yarn can have a count
in a range between about 30 Ne (177 denier). In one example, the
staple yarn can have count in a range between about 40 Ne (133
denier). In another example, the staple yarn has a count of about
60 Ne (88.6 denier). In another example, the staple yarn has a
count of about 70 Ne (75.9 denier). In another example, the staple
yarn has a count of about 80 Ne (66.4 denier). In one example, the
warp yarn is 2-ply yarn. In another example, the warp yarn is a
3-ply yarn.
[0025] The woven fabric also includes continuous filament, high
bulk yarns. In one example, the high bulk yarns are polyethylene
terephthalate (PET) filament yarns. While the continuous filament,
high bulk yarn are primarily formed from PET, in alternative
embodiments, the continuous filament, high bulk yarn are formed
from other synthetic filaments, such as polylactic acid (PLA)
fiber, polypropylene (PP) fibers, and polyamide fibers. The
continuous filament, high bulk yarns can have a range of yarn
counts. For instance, in one example, the continuous filament, high
bulk yarn can have count in a range between about 20 denier to
about 250 denier (21 Ne). The high bulk yarns can have range of
number of filaments per yarn, such as between 100 to about 250
filaments per yarn. More than 250 filaments per yarn or less than
100 filaments per yarn are possible.
[0026] Embodiments of the present disclosure include the continuous
filament, high bulk yarns dyed prior to fabric formation. For
example, the continuous filament, high bulk yarn can be a
dope-dyed, continuous filament yarn. In another example, the
continuous filament, high bulk yarn can be dyed using a disperse
dyes via package dyeing process (not shown). As used herein, a
"dyed continuous filament yarn" means a yarn dyed prior to fabric
formation whereby coloring agents are within the morphology of the
filaments that form the yarns. In one example, the high bulk
texturized continuous filament yarns may be a polyethylene
terephthalate (PET) continuous filament yarns and the staple spun
yarns are can be formed from natural fibers, e.g. cotton
fibers.
[0027] A high bulk yarn as used herein refers to continuous
filament yarn having a higher thickness for an equivalent yarn
count. Yarn thickness is measured by observing a distance that is
perpendicular to a length direction of the yarn that just contains
all of the filaments of the yarn. Specifically, the distance can be
distance between parallel planes that just contact the outer most
filaments. Such a distance can be determined using image analysis
techniques and the like. For instance, yarn thickness can be
measured by fixing a yarn with little to no tension cross-wise with
respect to a length scale. The thickness is the distance from two
parallel lines (or planes) that just contain the outer most
filaments. As used herein the high bulk yarns have a thickness that
ranges from about 0.5 mm to about 5.0 mm for yarn counts between
about 50 and about 250 denier. In one example, the high bulk yarns
have a thickness that ranges from about 1.0 mm to about 5.0 mm for
a 20 denier yarn. In one example, the high bulk yarns have a
thickness that ranges from about 1.0 mm to about 5.0 mm for a 75
denier yarn. In one example, the high bulk yarns have a thickness
that ranges from about 1.0 mm to about 5.0 mm for a 100 denier
yarn. In one example, the high bulk yarns have a thickness that
ranges from about 1.0 mm to about 5.0 mm for a 150 denier yarn. In
one example, the high bulk yarns have a thickness that ranges from
about 1.0 mm to about 5.0 mm for a 175 denier yarn. In one example,
the high bulk yarns have a thickness that ranges from about 1.0 mm
to about 5.0 mm for a 150 denier yarn. In one example, the high
bulk yarns have a thickness that ranges from about 1.0 mm to about
5.0 mm for a 200 denier yarn. In one example, the high bulk yarns
have a thickness that ranges from about 1.0 mm to about 5.0 mm for
a 250 denier yarn.
[0028] The inventors have also characterized the high bulk yarns in
terms of a bulk ratio. The yarn thickness of yarns described herein
may about 10% to about 300% greater thickness than a similar yarn
having the same yarn denier. The bulk ratio is a ratio of a first
yarn thickness Y1 to a second yarn thickness Y2, where the first
yarn and second yarn have similar yarn counts and number of
filaments per yarn. The yarn thickness Y1 and Y2 are illustrated in
exemplary filaments illustrated in FIG. 6. The high bulk yarns as
described herein have a bulk ratio of at least 1.20. For instance,
the bulk ratio may be between 1.1 to about 3.0. For purposes of
determining the bulk ratio, the yarn thickness is measured as
described above. This process is repeated for two yarns, one yarn
formed as described herein and the second yarn being a convention
yarn having the same count. The bulk ratio is calculated.
[0029] The continuous filament, high bulk yarn can be processed via
melt spinning followed by texturizing method 600 illustrated in
FIG. 4 using the texturing apparatus 500 illustrated in FIGS. 3A
and 3B. Typical melt spinning system, although not illustrated, is
apparent to those of skill in the art, includes a polymer storage
unit, a melt spinning unit, and a take-up system. Each component of
the melt spinning system will be described next.
[0030] As is typical in melt spinning, polymer resin is fed from a
storage unit to the melt spinning unit in the form of polymer
chips. The polymer chips are dried to remove moisture. The melt
spinning system can be used for form range of continuous filament
yarn types, such as a fully oriented yarn, a partially oriented
yarn, or a low oriented yarn. The melt-spinning unit includes one
or more extruders, a spin beam, a spin pack assembly. In
embodiments where the high bulk continuous filament yarn is dope
dyed or solution dyed, a color master batch is dossed via a
gravimetric feeder as needed to obtain the desired color. The
polymer is melted and homogenized in an extruder, which advances
the polymer melt line to the spin beam. The spin beam consists of a
manifold that distributes the molten polymer and a melt pump. The
temperature of a PET polymer melt in the spin beam, for example, is
between about 280.degree. C. to about 290.degree. C. From the spin
beam, the polymer melt flows into the spin pack assembly. The spin
pack assembly consists of a filter and spinnerets. The filter
removes impurities from the polymer melt and spinnerets converts
polymer into filaments. The filter may include fine metallic sand
particles as part of a filter medium. Filament formation occurs
when the polymer melt is ejected out of the spin pack assembly
through the spinnerets to form filaments, which are drawn via the
take-up system.
[0031] The take-up system further processes the filaments to quench
and draw as desired for the application. After quenching, a finish
applicator applies a spin finish to the filaments to reduce
friction, improve binding, and prevent static charge. The finish
applicator spreads the spin finish uniformly over the surface of
the drawn filaments. An optional intermingling nozzle may be used
to impart nodes in the filaments to bind the individual filaments
together and aid subsequent winding/unwinding operations. The
filaments are then wound onto a yarn package with a winder. In one
example, certain process parameters and melt spinning system
components have been found to be beneficial in forming continuous
filament high bulk yarns including: spinneret arrangement; use of
fine metallic sand for filtration of spinning lower denier per
filament (DPF) yarns; minimized spin finish applicator distance
from the spinneret; spin finish based on an emulsion for deep
penetration of spin finish into filament bundle; and migration
nozzles to uniformly distribute spin finish oil over the surface of
the yarn.
[0032] After melt-spinning, the filament yarn is textured as
described herein to form the high-bulk continuous filament yarns
using the texturing apparatus 500 as illustrated in FIGS. 3A and 3B
and texturing method process 600 illustrated in FIG. 4. The
texturizing apparatus 500 increases the overall yarn bulk, texture,
and volume of the continuous filament yarn for a given linear
density as discussed above. Specifically, the texturizing apparatus
500 imparts twist into the filament yarn. The twisted filament yarn
is then heat set in a "twisted" configuration. After the twist is
heat set and cooled, additional entangling steps add further bulk
and softness to the yarn. The result is a unique, high bulk
continuous filament yarn that has more bulk and greater volume than
a similar continuous filament yarn having the same denier and
number of filaments per yarn. The texturing apparatus 500 and the
related process 600 will be described in detail next.
[0033] Referring to FIGS. 3A and 3B, the texturing apparatus 500
includes a first texturing unit 410, a second texturing unit 415,
and a take-up unit 420. In general, a filament threadline 520 is
deformed, or twisted, and set, via the first texturing unit 410.
The second texturing unit 415 imparts further bulk and loft to the
filament threadline 520 and sets the added bulk to form a high bulk
filament threadline 522. The take-up unit 420 collects the high
bulk filament threadline 522 into a suitable package for further
processing. Accordingly, the texturing apparatus 500 subjects the
threadline 520 to twist-entangling process to impart bulk. The
apparatus 500 is schematically illustrated in FIGS. 3A and 3B for
illustrative purposes. In one example, however, the thread
path--the line along which threadline 520 and 522 travel through
the texturing apparatus 500 from the yarn source 501 to the final
wound package can be substantially linear for optimum processing.
The first texturing unit 410, second texturing unit 415, and a
take-up unit 420 will be described next.
[0034] Continuing with FIGS. 3A and 3B, the first texturing unit
410 includes a yarn source 501, an input feed roller 502, a first
heating unit 503 (sometimes referred to as a primary or initial
heater), a cooling plate 504, a false-twist unit 505, and
intermediate rollers 506. The input yarn source 501 is preferably a
package comprising a partially oriented filament yarn (POY). A POY
can be deformed during subsequent heating phases along the
apparatus 500. More specifically, the POY can withstand subsequent,
multiple rearrangements of internal fiber morphology resulting from
multiple heating-deformation-cooling cycles used in apparatus 500
to create the high bulk yarns as described herein. A POY yarn as
used herein is referred to as a threadline 520. In one example, the
POY filament yarn has about 144 filaments with a DPF of about 1.0.
It should be appreciated that more or less filaments can be used
depending on spinning system parameters. It should be further
appreciated that in alternative embodiments, the input yarn source
501 can be an oriented yarn package, a low oriented yarn (LOY)
package, or a threadline from the output of the melt-spinning
system. The input rollers 502 guide the threadline 520 into first
heating unit 503 and aids in drawing the threadline 520.
[0035] Continuing with FIGS. 3A and 3B, the first heating unit 503
exposes the threadline 520 to thermal energy while the false twist
unit 505 imparts a desired level of twist into the threadline 520.
The first heating unit 503 can be a typical thermal heating device
that exposes the threadline 520 to a desired temperature, dependent
in part on filament composition. The cooling plate 504 is
maintained at ambient or below ambient temperatures and exposes the
threadline 520 to temperatures below the temperatures in the first
heating unit 503. The temperature of the cooling plate 504 is
selected to set deformation imparted into threadline 520 by the
twist unit 505 and by drawing of filaments due to operation of
input rollers 502 and intermediate rollers 506. The false-twist
unit 505 is a device configured to impart false twist into the
filament bundle that comprises the threadline 520. In particular,
the false twist unit 505 includes a pair of friction disks 517 and
519 that are used to twist the threadline 520. While friction disks
are illustrated, other means to impart twist may be used as well,
such as rotating belts and the like. The false twist unit 505
delivers threadline 520 to the intermediate rollers 506.
[0036] Continuing with FIGS. 3A and 3B, the input rollers 502 and
intermediate rollers 506 operate at first and second rotational
speeds S1 and S2, respectively, to draw the threadline 520 to the
desired draw ratio. The rotational speed S2 of intermediate rollers
506 is greater than the rotational speed S1 of input rollers 502,
thereby drawing the threadline 520 as it passes through the first
heating unit 503, cooling plate 504, and false twist unit 505.
Typically, the draw ratio of the threadline is related to the ratio
of the second speed S2 to the first speed S1. Speeds S1 and S2 can
be selected as needed depending on the application and desired yarn
parameters. In any event, the first texturing unit 410 is
configured to simultaneously draw the threadline 520, apply twist
along the threadline 520, and set the threadline 520 prior to the
threadline entering the second texturing unit 415. The threadline
520 entering the second texturing 520 unit 415 can be referred to
as a twisted or bulked threadline 521 (see FIG. 3A).
[0037] Continuing with FIGS. 3A and 3B, the threadline 520 exits
the first texturing unit 410 and enters the second texturing unit
415 as a twisted threadline 521. The second texturing unit 415
includes an intermingling jet 507, jet-overfeed rollers 508, and
the second heating unit 509. In the second texturing unit 415,
further bulk is imparted to the threadline 521 via intermingling
jet 507. The added bulk is heat set via the second heating unit 509
to yield a high bulk threadline 522. The intermediate rollers 506
also control tension along the threadline as it enters the
intermingling jet 507. The intermingling jet 507 includes one or
more nozzles and a gas source (not shown), such as air. The
intermingling jet 507 injects air into the threadline 520 via the
nozzles to induce filament entanglements and add bulk along the
threadline at the location following the intermediate rollers 506.
The intermediate rollers 506 operate at rotational speed that is
greater than the rotational speed of the rollers 502. Jet-overfeed
rollers 508 operate at a rotational speed that lower than the
intermediate rollers 506 so to overfeed filaments into jet 507.
Jet-overfeed rollers 508 operate at a rotational speed that is
about the same as speed of the output rollers 510. The rollers 508
overfeed filaments in the threadline into the second heating unit
509. The second heating unit 509 can be a typical thermal heating
device that exposes the threadline to a desired temperature. From
the second heating unit 509, the high bulk threadline 522 enters
the take-up unit 420.
[0038] As can be seen FIG. 3A, the take-up unit 420 includes output
delivery rollers 510, an oil applicator 511, and a winding unit
512. The output delivery rollers 510 control tension of the
threadline 522 and present the threadline 522 to an oil applicator
511. The oil applicator 511 is configured to apply a lubricant to
the threadline 522. The winding unit 512 can be a typical winder,
such a random or precision winder, designed build the threadline
522 a suitable yarn package for further processing.
[0039] It should be appreciated that the apparatus can be
configured to process multiple threadlines 520 and multiple yarn
packages for use in later textile operations. As such a texturing
system may include a plurality of similar texturing apparatuses 500
as described above.
[0040] Turning now to FIG. 4, a process 600 used to form a high
bulk continuous filament yarn using the apparatus 500 according to
an embodiment of the present disclosure is illustrated. Process 600
initiates with a yarn input step 602 where the yarn source supplies
the continuous filament threadline to the first heating unit 503
and false twist unit 505 (FIG. 3A). Next, a heating step 604,
exposes the threadline to an elevated temperature. For example, the
heating unit may expose the continuous filament threadline to the
polymer glass transition temperature or higher. After the heating
step 604, a cooling step 608 cools the threadline with a cooling
plate. During the heating step 604 and cooling step 608, a false
twist step 612 imparts twist to the continuous filament threadline
via a false twist unit. During the false twisting step 612, the
continuous threadline is also subject to drawing. Specifically, the
speed differential between input rollers 502 and intermediate
rollers 506 draws the filament threadline while the false twist
unit 505 applies twist to the threadline. The twisting step 612 and
drawing step 616 occur simultaneously during the heating step 604
and cooling step 608, such that the continuous filament threadline
is subject to deformation (twist and attenuation or drawing) and
setting in one phase of the process 600.
[0041] Continuing with FIG. 4, an intermingling step 620 adds
additional bulk to threadline. A jet, such as jet 507 shown in FIG.
3A, entangles the filaments in threadline. The intermingling step
620 is included to add softness to the yarn, which results in
softness and bulk in the final woven fabric. An overfeeding step
624 overfeeds the threadline into the second heating unit to aid in
entanglement and setting of the deformed, bulked filament. The
overfeeding step 624 aids in jet entangling. A second heating step
628 sets the overfed, bulked threadline to yield a high bulk
continuous filament yarn as described herein. Next, a tension step
is used to control or adjust tension along the threadline via
output rollers 510 and winding speed at winder unit 512. See 510
and 512 in FIG. 3A. An oil application step 536 imparts a lubricant
to the threadline. A winding step 640, winds the high bulk
continuous filament yarn onto suitable package with uniform package
hardness to retain bulk in the yarn 522. Following winding, the
yarn package can be used during weaving a weft yarn 40 as described
above. In alternative embodiments, the yarn package may be used in
the warp. However, in such an embodiment where the warp yarns are
high bulk continuous filament yarns, the weft yarns 40 would be
staple yarns.
[0042] The high bulk continuous filament yarns as described herein
can be used as weft yarns as illustrated. In such an embodiment,
the warp yarns are staple spun yarns. For instance, the warp yarns
would not include any filament based yarns. In an alternative
embodiment, the high bulk continuous filament yarns as described
herein can be used as warp yarns and the woven construction can be
such that warp yarns are exposed on the face 12 of the woven
fabric. In such an embodiment, the weft yarns are staple spun
yarns. For instance, the weft yarns would not include any filament
based yarns.
[0043] It should be appreciated that the texturing apparatus and/or
the texturing method 600 can be in-line with a weaving operation in
a vertically integrated plant, or it may form a separate processes,
the result of which is a yarn package for use in other textile
operations, such as weaving, knitting, and the like.
[0044] Another embodiment of the present disclosure is a method of
making the woven fabric described above. Turning to FIG. 5, a
method 200 of making woven fabric 10 according to an embodiment of
the disclosure is illustrated. The method 200 includes yarn
formation step 210. Yarn formation 210 for the warp yarns can
include staple yarn formation step 212 and filament yarn formation
step 214. Staple yarn formation 212 may utilize any number of
staple yarn formation systems and sub-systems as described above
with respect to the staple yarns. Filament yarn formation 214
involves melt spinning continuous filament yarns and texturizing
the filament yarns to impart high bulk as described above.
[0045] After yarn formation 210, the yarns are warped in a warping
step 220. The warping step 220 is where the warp yarn ends are
removed from their respective yarn packages, arranged in a parallel
form, and wound onto a warp beam, as is known to a person of skill
in the weaving arts. The warping step 220 also includes a sizing
step where a sizing agent is applied to each warp yarn to aid in
fabric formation. The warping step 220 results in a warp beam of
yarns that can be positioned on a mounting arm of a weaving loom so
that the warp yarns can be drawn through the loom components
according to the desired weave design.
[0046] Continuing with FIG. 5, a weaving step 240 forms a woven
fabric using a weaving loom. More specifically, in the weaving step
240, the warp yarns are drawn-in (not shown) through various
components of a weaving loom, such as drop wires, heddle eyes
attached to a respective harness, reed and reed dents, in a
designated order as is known in the art. Next, weaving proceeds
through fabric a formation phase. The fabric formation phase
creates a shed with the warp yarns that the weft or picks are
inserted through across the width direction of the loom to create
the desired woven fabric construction. Various shedding motions may
be used, for example, such as cam, dobby, or jacquard shedding
motions. The formation phase can utilize different weft insertion
techniques, including air-jet, rapier, or projectile type weft
insertion techniques.
[0047] During the formation phase of the weaving step 240, weft
yarns 40 are interwoven with the warp yarns 20 to define the woven
design construction. Exemplary fabric woven constructions can
include but are not limited to: plain weaves; basket weaves, satins
(e.g. satin dobby base, satin stripe satin 5/1, satin 4/1 satin;
4/1 satin base strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1
satins); rib weaves (e.g. 2.times.1 rib weave; 2.times.2 rib weave;
or 3.times.1 rib weave); twill weaves, and oxford weaves. In one
example, the woven fabric is a plain weave. In another example, the
woven fabric is a satin weave. In another example, the woven fabric
is a 4/1 satin. In another example, the woven fabric is a 4/1 satin
dobby diamond weave. In another example, the woven fabric is a 4/1
satin dobby stripe. In another example, the woven fabric is a 4/1
satin jacquard weave. The weaving step forms a woven fabric with a
warp end density between about 50 warp ends per inch to about 300
warp ends per inch. The weft yarns can be inserted in such a manner
to define a weft or pick density between about 50 picks per inch to
about 300 picks per inch. Exemplary weaving constructions are
summarized in table 1 below.
TABLE-US-00001 TABLE 1 Example Description 1 Warp: 60s Cotton, Weft
150D dope Dyed High bulk, PET fiament yarn. EPI = 165. PPI = 90
Width = 90 inchs to 130 inchs Weave type 4/1 Satin; 2 Warp: 40s
Cotton Weft 150D dope dyed High bulk, PET fiament yarn EPI = 132,
PPI = 72 Width = 90 inchs to 130 inchs Weave type 4/1 Satin 3 Warp:
30s Cotton Weft 150D dope dyed High bulk, PET fiament yarn EPI =
76, PPI = 68 Width = 90 inchs to 130 inchs Weave type Percale 4
Warp: 60s Cotton, Weft 150D dope dyed High bulk, PET fiament yarn.
EPI = 165. PPI = 90 Width = 90 inchs to 130 inchs Weave type 4/1
Satin base dobby stripe, Jacquard
[0048] Continuing with FIG. 5, after the weaving step 240, the
woven fabric passes through desizing and bleaching step 250.
Desizing may be accomplished with enzymes. Bleaching may include
use of typical bleaching agents, such as hydrogen peroxide
bleaching. During bleaching, the fabric is bleached with above
chemicals and the cotton staple yarns are bleached. Step 250 may
include singing the fabric.
[0049] Next, a dying and finishing step 270 applies color and one
or more functional agents to the fabric. In an embodiment with
cotton staple yarns, the cotton staple yarns are dyed with reactive
dyes using a pad dry, pad steam, cold pad batch methods. Because
the high bulk continuos filament yarns are dope or solution dyed,
only the staple yarns are dyed during step 270. The dying step
should match the natural fiber staple yarns to the high bulk, dope
or solution dyed yarns. Step 270 may also include applying a
composition including one or more of the functional agents to the
woven fabric. The functional agents may include a softener,
antimicrobial agent, etc. In one example, the finish composition
may contain a silicone at about 5-20 gpl. Next, excess moisture is
removed the woven fabric by advancing the fabric through a heating
machine. Heating machines may be heated steam, infrared, hot air,
surface rolls, hot oil can, through-air ovens, and like machines.
After drying, the woven fabric may be sanforized and calendared to
adjust the hand and better control shrinkage.
[0050] Continuing with FIG. 5, after the dyeing and finishing step
270, the woven fabric is assembled into the article in an assembly
step 280. As illustrated, the assembly step 280 includes cutting
the woven fabric to the size for the intended bedding article.
During assembly, the bedding articles are constructed so that the
face 12 of the woven fabric 10 is arranged to be the face of the
bedding article. More specifically, the bedding articles are
constructed so that face 12 of the woven fabric, a majority of
which include exposed high bulk, continuous filament yarns, defines
the skin-contact portion of the bedding articles. Thus, the high
bulk continuous filament yarns define a predominate portion of the
face of the bedding article. After the assembling step 280, a
packaging step 290 places the bedding article in a suitable
packaging for shipment.
[0051] Embodiments of the above described woven fabric and related
methods result in improve end-use properties. Tables 2-6 below
summarizes data used to evaluate woven fabrics formed as described
herein. It should be appreciated that the below examples do not
limit use of high bulk continuous filament yarns as warp yarns
where the weft yarns are staple yarns. A person of skill in the art
would appreciate that similar results may be possible when using
high bulk continuous filament yarns in the warp that are exposed to
the face of the fabric.
TABLE-US-00002 TABLE 2 A CONSTRUCTION DETAIL: 60*150D/180*90
Testing Parameter Test Method Result 1 Thread Count ASTM D3775 270
2 GSM ASTM D3776 127 3 Blend AATCC 20/21 A Cotton Yarn/PET Yarn
TABLE-US-00003 TABLE 3 A CONSTRUCTION DETAIL: 60*150D/180*90
Testing Parameter Test Method Result 1 Stain Release Property AATCC
130 270 a Coffee AATCC 20/21 A 4.5 b Red Wine 4.5 c Ketchup 4.5
TABLE-US-00004 TABLE 4 A CONSTRUCTION DETAIL: 60*150D/180*90
Testing Parameter Test Method Result 1 Durable Press AATCC 143. 270
After after 5 & 10 washes AATCC 20/21 A 3.5
TABLE-US-00005 TABLE 5 COLOR FASTNESS Testing Parameter Test Method
Result 1 Fastness to Light AATCC 16 (option 3) 4.5 2 Fastness to
Washing AATCC 61 2(A) Shade change 4-5 Staining 4-5 Self Staining
4-5 3 Fastness to Crocking AATCC-8 or 116 a Dry 4-5 b Wet 4 5 Color
Fastness to Chlorine Bleach AATCC 001 4.0 6 Color Fastness to AATCC
001 4.0 Non-Chlorine Bleach
TABLE-US-00006 TABLE 6 Testing Parameter Test Method Results 1
Dimensional Stability (3HL) AATCC-135 a Warp -2.5% b Weft -1.0% 2
Tensile Strength AATCC D 5034 a Warp (LBS) 68 b Weft (LBS) 154 3
Tearing Strength ASTM D 1424 a Warp (LBS) 5.49 b Weft (LBS) 11.26 4
Seam Slippage ASTM D 434 a Warp (LBS) 45 b Weft (LBS) 33 5 Seam
Strength ASTM D 1683 a Warp (LBS) 44 b Weft (LBS) 32 6 Pilling ASTM
D 4970 4 7 DP Rating @ 5 washes AATCC 124 3.5
[0052] While the disclosure is described herein using a limited
number of embodiments, these specific embodiments are not intended
to limit the scope of the disclosure as otherwise described and
claimed herein. The precise arrangement of various elements and
order of the steps of articles and methods described herein are not
to be considered limiting. For instance, although the steps of the
methods are described with reference to sequential series of
reference signs and progression of the blocks in the figures, the
method can be implemented in a particular order as desired.
* * * * *