U.S. patent application number 15/893673 was filed with the patent office on 2018-10-25 for recycled fabric structure, knitted vamp cloth and method of manufacturing yarn.
The applicant listed for this patent is LONG JOHN TSUNG RIGHT INDUSTRIAL CO., LTD.. Invention is credited to WEN-TSAO WEN, Yu-Chang Wen.
Application Number | 20180305847 15/893673 |
Document ID | / |
Family ID | 60764439 |
Filed Date | 2018-10-25 |
United States Patent
Application |
20180305847 |
Kind Code |
A1 |
WEN; WEN-TSAO ; et
al. |
October 25, 2018 |
RECYCLED FABRIC STRUCTURE, KNITTED VAMP CLOTH AND METHOD OF
MANUFACTURING YARN
Abstract
A recycled fabric structure is provided, which includes a
plurality of types of blended yarn arranged by weaving or
interlacing. Wherein, each of the types of the blended yarn has a
plurality of first fibers and a plurality of second fibers
vertically arranged and interloped with each other. The plurality
of first fibers accounts for 30% to 50% of the total weight of the
blended yarn. The first fiber is a recycled fiber.
Inventors: |
WEN; WEN-TSAO; (Changhua
County, TW) ; Wen; Yu-Chang; (Changhua County,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LONG JOHN TSUNG RIGHT INDUSTRIAL CO., LTD. |
Changhua County |
|
TW |
|
|
Family ID: |
60764439 |
Appl. No.: |
15/893673 |
Filed: |
February 11, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 15/0033 20130101;
D03D 15/0027 20130101; D02G 3/04 20130101; D10B 2331/02 20130101;
D01G 13/00 20130101; D10B 2201/02 20130101; D10B 2201/24 20130101;
D02G 3/34 20130101; D01G 11/04 20130101; D03D 15/0077 20130101;
D04B 21/202 20130101; D02G 3/346 20130101; D10B 2401/00 20130101;
D01G 11/00 20130101; D10B 2331/04 20130101; D10B 2501/043 20130101;
A43B 1/04 20130101 |
International
Class: |
D03D 15/00 20060101
D03D015/00; D02G 3/04 20060101 D02G003/04; D02G 3/34 20060101
D02G003/34; D01G 11/00 20060101 D01G011/00; D01G 13/00 20060101
D01G013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 25, 2017 |
TW |
106205803 |
Claims
1. A recycled fabric structure, comprising: a plurality of types of
blended yarn arranged by weaving or knitting, wherein each of the
types of blended yarn has a plurality of first fibers and a
plurality of second fibers vertically arranged and interlooped with
each other; the plurality of first fibers accounts for 30% to 50%
of a total weight of the blended yarn; the plurality of first fiber
is a recycled fiber generated by a machinery fiber opening process
applied to a recycled knitted cloth; the blended yarn is an one-ply
yarn and has a random wire diameter and a color difference; and a
slub part of the one-ply yarn is formed by a part of the plurality
of first fibers.
2. The recycled fabric structure of claim 1, wherein the part of
the plurality of first fibers comprises a nep.
3. The recycled fabric structure of claim 2, wherein the nep of
each of the plurality of first fibers has a random size and forms
the slub part of the one-ply yarn.
4. The recycled fabric structure of claim 1, wherein the recycled
knitted cloth comprises a knitted vamp cloth dyed with at least two
colors.
5. The recycled fabric structure of claim 1, wherein the slub of
the plurality of first fibers has a random color.
6. The recycled fabric structure of claim 1, wherein the lengths of
the plurality of first fibers and the plurality of second fibers
are from 30 to 40 mm.
7. The recycled fabric structure of claim 1, wherein the plurality
of first fibers comprises at least one type of yarn forming the
recycled knitted cloth, and the type of yarn forming the recycled
knitted cloth has a denier value from 75D to 600D and a
polyfilament yarn number from 24 f to 72 f.
8. The recycled fabric structure of claim 1, wherein a fiber
elongation of the blended yarn is a value from 10% to 25%.
9. The recycled fabric structure of claim 1, wherein a fiber
strength of the blended yarn is from 20 to 40 cN/tex.
10. The recycled fabric structure of claim 1, wherein a denier
value of the blended yarn is from 150D to 600D.
11. The recycled fabric structure of claim 1, wherein a thread
count of the blended yarn is from 6 s to 20 s.
12. The recycled fabric structure of claim 1, wherein the recycled
fiber comprises one of cotton, polyester, polyamide or rayon, or a
combination thereof.
13. A knitted vamp cloth, comprising the recycled fabric structure
of claim 1.
14. A method of manufacturing yarn, comprising steps as follows:
cutting a knitted cloth into a predetermined size; applying an
machinery fiber opening process to the cut knitted cloth to form a
plurality of first fibers having a predetermined length, wherein a
part of the plurality of first fibers comprises a nep; mixing the
plurality of first fibers and the plurality of second fibers to
form a evenly mixed cotton layer; and applying a cotton carding
process and a doubling process to the mixed cotton layer, and
applying a ring-spinning process to form an one-ply yarn; wherein,
the one-ply yarn has a random wire diameter and a color difference,
the plurality of first fibers accounts for 30% to 50% of a total
weight of the one-ply yarn, the nep of the plurality of first
fibers has a random size, and a part of the plurality of first
fibers forms a slub part of the one-ply yarn.
15. The method of claim 14, wherein the knitted cloth is a knitted
vamp cloth dyed with at least two colors.
16. The method of claim 14, wherein the lengths of the plurality of
first fibers and the plurality of second fibers are from 30 to 40
mm.
17. The method of claim 15, wherein a slub of the plurality of
first fibers has a random color.
18. The method of claim 14, wherein a denier value of the one-ply
yarn is in a range from 150D to 600D.
19. The method of claim 14, wherein a thread count of the one-ply
yarn is from 6 s to 20 s.
20. The method of claim 14, wherein the plurality of first fibers
comprises at least one type of yarn forming the recycled knitted
cloth, and the type of yarn forming the recycled knitted cloth has
a denier value from 75D to 600D and a polyfilament yarn number from
24 f to 72 f.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Taiwan Patent
Application No. 106205803, filed on Apr. 25, 2017 at Taiwan
Intellectual Property Office, the contents of which are hereby
incorporated by reference in their entirety for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present application is related to a fabric structure, in
particular, a recycled fabric, a knitted vamp cloth and a method of
manufacturing yarn.
2. Description of the Related Art
[0003] Daily life presents new challenges, and to face those
challenges, new products are constantly being developed. The
textile industry, and those industries related thereto have
provided new products to face such challenges. The advancing
developments continue to evolve over time, each step improving
daily quality of life.
[0004] It is typical to cut a textile from a textile roll into a
demanded size for use in a product. The remaining material may be
unsuitable for many applications, and will likely be discarded. In
today's environmentally friendly world, it is critical to recycle
waste when possible, in order to reduce environmental pollution. As
the trend of environmental awareness continues to grow, efficient
use of resources, and methods of recycling or reusing materials are
topics of concern.
[0005] Fancy yarn is a type of yarn which is identified by having
special color distributions, sizes and wire diameters. In order to
provide the yarn a variability of wire diameter differences, a
two-ply yarn is often manufactured by plying, twinning, false
twisting, adding additional neps and twisting in a cotton mixing
process, or applying an air-jet texture process to a filament tow.
To further improve the complexity (such as color) of the fancy
yarn, a process of adjusting the spinning, dyeing process, or
adding a variety of additives in raw materials is required, which
increases the cost so that the yarn cannot be simply made.
[0006] In summary, the inventor of the present application designs
a recycled fabric structure, a knitted vamp cloth and the method of
manufacturing the same are provided after years of painstaking
research, which improve the defects presented in the prior art and
will further improve the practical implementation in
industries.
SUMMARY OF THE INVENTION
[0007] According to the problems mentioned above, the subject of
the present application is to provide a recycled fabric structure,
a knitted vamp cloth and the manufacturing method thereof, and
utilizing these materials and this method, to become able to
significantly reduce environmental pollution and achieve an
efficient use of the resources.
[0008] Based on the above subjects, the present invention provides
a recycled fabric structure, which comprises: a plurality of types
of blended yarn arranged by weaving or interlacing, wherein each of
the types of blended yarn has a plurality of first fibers and a
plurality of second fibers vertically arranged and twisted with
each other; the first fibers accounts for 30% to 50% of a total
weight of the blended yarn; the first fiber is a recycled fiber
generated by a machinery fiber opening process applied to a
recycled knitted cloth; the blended yarn is a one-ply yarn and has
a random wire diameter and a color difference; and a slub part of
the one-ply yarn is formed by a part of the plurality of first
fibers.
[0009] Preferably, the part of the plurality of first fibers
comprises a nep.
[0010] Preferably, the nep of each of the plurality of first fibers
has a random size, and forms the slub part of the one-ply yarn.
[0011] Preferably, the recycled knitted cloth comprises a knitted
vamp cloth dyed with at least two colors.
[0012] Preferably, a slub of the plurality of first fibers has a
random color.
[0013] Preferably, the lengths of the plurality of first fibers and
the plurality of second fibers are from 30 to 40 mm.
[0014] Preferably, the plurality of first fibers comprises at least
one type of yarn forming the recycled knitted cloth, and the type
of yarn forming the recycled knitted cloth has a denier value from
75D to 600D and a polyfilament yarn number from 24 f to 72 f.
[0015] Preferably, a fiber elongation of the blended yarn is a
value from 10% to 25%.
[0016] Preferably, a fiber strength of the blended yarn is from 20
to 40 cN/tex.
[0017] Preferably, a denier value of the blended yarn is from 150D
to 600D.
[0018] Preferably, the thread count of the blended yarn is from 6 s
to 20 s.
[0019] Preferably, the recycled fiber comprises one of cotton,
polyester, polyamide or rayon, or a combination thereof.
[0020] Based on the above subjects, the present invention provides
a knitted vamp cloth, which comprises the aforementioned recycled
fabric structure.
[0021] Based on the above subjects, the present invention provides
a method of manufacturing a yarn, comprising steps as follows:
cutting a knitted cloth into a predetermined size; applying an
machinery fiber opening process to the cut knitted cloth to form a
plurality of first fibers having a predetermined length, wherein a
part of the plurality of first fibers comprises a nep; mixing the
plurality of first fibers and the plurality of second fibers to
form an evenly mixed cotton layer; and apply a cotton carding
process and a doubling process to the mixed cotton layer, and
applying a ring-spinning process to form an one-ply yarn; wherein,
the one-ply yarn has a random wire diameter and a color difference,
the plurality of first fibers accounts for 30% to 50% of the total
weight of the blended yarn, a nep of the plurality of first fibers
has a random size, and a part of the plurality of first fibers
forms a slub part of the one-ply yarn.
[0022] Preferably, the knitted cloth is a knitted vamp cloth dyed
with at least two colors.
[0023] Preferably, the lengths of the plurality of first fibers and
the plurality of second fibers are from 30 to 40 mm.
[0024] Preferably, the slub of the plurality of first fibers has a
random color.
[0025] Preferably, a denier value of the one-ply yarn is in a range
from 150D to 600D.
[0026] Preferably, the thread count of the one-ply yarn is 6 s to
20 s.
[0027] Preferably, the plurality of first fibers comprises at least
one type of yarn forming the recycled knitted cloth, and the type
of yarn forming the recycled knitted cloth has a denier value from
75D to 600D and a polyfilament yarn number from 24 f to 72 f.
[0028] According to the above descriptions, the recycled fabric
structure, the knitted vamp cloth and the method of manufacturing
the same may have one or more following advantages:
[0029] (1) Capability to be spun by a short fiber and manufacture
an one-ply yarn having randomly distributed wire diameters. Since
the yarn is one-ply yarn, it is able to control and make the
product yarn still have special patterns when the wire diameter is
relatively small.
[0030] (2) The opened knitted cloth generates neps easily. During
the spinning process, fibers containing neps may generate slubs,
and therefore form different wire diameters. The product yarn may
be generated without depending on the means of plying or adding
neps.
[0031] (3) The present application may form types of yarn which are
natural and have irregular colors, and which may be generated by
reconstituting the remaining material consisting of knitted cloth.
In particular, the present application details recycling of the
remaining dyed knitted cloth materials which have various colors,
and possess special color distributions and pattern differences
without dying the yarn.
BRIEF DESCRIPTION OF THE DOUBLINGS
[0032] FIG. 1 is a schematic diagram of the recycled fabric
structure of the first preferable embodiment of the present
application.
[0033] FIG. 2 is a schematic diagram of a blended yarn illustrated
in FIG. 1.
[0034] FIG. 3 is a schematic diagram of a blended yarn illustrated
in FIG. 1.
[0035] FIG. 4 is a schematic diagram of a blended yarn illustrated
in FIG. 1.
[0036] FIG. 5 is a schematic diagram of a blended yarn illustrated
in FIG. 1.
[0037] FIGS. 6A and 6B are flow charts of a manufacturing process
of the recycled fabric structure of the first preferable embodiment
of the present application.
[0038] FIGS. 7A and 7B are schematic diagrams of the second
preferable embodiment of the present application.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Hereinafter, the embodiments of the recycled fabric
structure 1 of the present application will be explained taken in
conjunction with the appending drawings. For ease of understanding,
the same elements are labeled by the same numerals in following
embodiments.
[0040] Please refer to FIGS. 1 to 5, which are schematic diagrams
of the recycled fabric structure 1 of the first preferable
embodiment of the present application. In the doublings, the
recycled fabric structure 1 comprises a plurality of blended yarn
10 arranged by weaving or interlacing. Wherein, each of the blended
yarn 10 has a plurality of cotton bars 12 vertically arranged and
intertwined with each other, and is arranged in a bar shape. The
plurality of cotton bars 12 have a plurality of first fibers 14 and
a plurality of second fibers 16 which are mixed evenly. Wherein,
the first fibers 14 are recycled fibers generated by a machinery
fiber opening process applied to a recycled knitted cloth. The
first fibers 14 account for 30%, 35%, 40%, 45% or 50% of the total
weight of the blended yarn. Wherein the blended yarn 10 is a
one-ply yarn and has a random wire diameter and a color difference.
Whereas a part of the plurality of first fibers 14 forms the slub
13 part of the one-ply yarn. That is, a part of the plurality of
first fibers 14 comprises a nep which has a random size, and forms
the slub 13 part of the one-ply yarn. In the present embodiment,
the blended yarn 10 is formed into loops, thereby the loops are
interlooped to each other and a knit is formed. The texture is
soft, with good wrinkle resistance, breathability, and greater
extensibility and flexibility.
[0041] Please refer to FIGS. 5, as well as 6A and 6B, the method of
manufacturing the recycled fabric structure 1 of the first
preferable embodiment of the present application will be described,
comprising the steps as follows:
[0042] Step 100: Recycling knitted cloth waste, and cutting the
knitted cloth waste into a size between 3 cm and 5 cm. The way of
cutting is two-paths cutting, which is beneficial to a subsequent
fiber opening process for forming spinable fiber. First, the
knitted cloth waste is applied with a vertical cutting 601 and
becomes bar shaped, then is applied with a horizontal cutting 602
and becomes block shaped, as shown in FIG. 6B. The cutting size and
method is not limited thereto and may be adjusted depending on
cloth types. The knitted cloth waste may comprise cotton,
polyester, polyamide or rayon. Wherein, the source of the knitted
cloth waste may be any type of remaining cloth material.
Specifically, the recycled knitted cloth waste of the present
application may be dyed knitted vamp cloth, for instance, the cloth
being dyed, printed or digitally printed by at least two colors may
be recycled, or the dyed knitted cloth obtained from different
sources may be mixed. Hence, a final product of the yarn does not
need to be applied with a dye process, and still possesses natural,
irregular colors.
[0043] Step 200: Fiber opening and cotton scotching; applying
machinery fiber opening, blending, opening and cleaning to the cut
knitted cloth waste by a needle-punch wheel so as to obtain an even
cotton layer. With special attention to FIG. 5, blending is a
process that mixes various types of fibers evenly, that is, mixing
a first fiber 14 and a second fiber 16 (e.g. artificial fiber)
which belong to different types but have similar qualities, and
form a mixed cotton layer. The opening and cleaning are processes
that release the fiber of the mixed cotton layer so that the mixed
fibers having block shape or bundle shape transform from a large
shape to a small shape, and impurities are removed. In addition,
the opening and cleaning may be performed by selection of the
combinations between different types of machines and beater
depending on the type and level of the fiber and the impurities
contained therein. In particular, the routine of the fiber opening
process of the present application maybe performed one time, two
times, three times, mostly five times, six times or seven times of
multiple fiber opening. The attrition rate of the fiber opening
process applied to the knitted cloth waste may be lower than 30%,
in some circumstances preferably 20% or in other circumstances
preferably 10%, and the length and the spinnability of the opened
fiber may be improved, by sustaining the routine of the fiber
opening process and reducing the tearing force during each
procedure of the fiber opening processes, or gradually increasing
the tearing force during the fiber opening process. Further, the
fiber opening process may control the fiber length after the
process, and for instance, may obtain a demanded fiber length by
controlling the processes of feeding, tearing and cutting.
Preferably, the fiber length is in the range of 30 mm to 40 mm, for
instance, and may be about 30 mm, 32 mm, 34 mm, 36 mm, 38 mm or 40
mm. For example, the purpose of controlling the fiber length
thereof may be achieved by stably feeding the fiber through a
conveyor wheel having high gripping force. During the process of
fiber opening process applied to the knitted cloth, since knitted
cloth is the fabric formed by the yarn interlooped and knitted to
each other, the friction generated during tearing may form a fiber
which has neps (fiber fast knot). However, the spinnability of the
fiber having neps still may be improved by controlling the fiber
length within predetermined ranges, for instance, controlling the
length so that each of the fibers has one or mostly two neps
thereon.
[0044] Step 300: Carding; carding the cotton roll or cotton layer
and arranging it accordingly, then simultaneously and repeatedly
removing impurities and fluff, keeping spinnable fiber, mixing
fibers and manufacturing cotton nets, improving the evenness
thereof and condensing the previous mentioned fibers into a
demanded cotton bar 12 which is also called a sleeve, in order to
be beneficial to subsequent processes.
[0045] Step 400: Doubling; doubling 6 to 8 of the cotton bars 12
(here means the sleeves) and drafting, in order to manufacture
drawn sleeves. This process straightens the mixed fibers and
arranges them in parallel with each other, doubles the drawn
sleeves having uneven thicknesses together and spins into the drawn
sleeves having even thicknesses. Further, this step removes the
remaining fluff and impurities. The structure is shown in FIGS. 3
and 4.
[0046] Step 500: Modeling; drafting and extending the cotton bars
12 (here means the sleeves) by an alternating process and a yarn
ring-spinning process, in order to make the fiber straighter and
more parallel. Further, the cotton bar 12 should have an
appropriate diameter so that the volume may be reduced.
Subsequently, a twisting process is performed so that a demanded
thinness and twistedness may be achieved and a blended yarn 10
having strength may be produced. Then, winding the blended yarn 10
on a bobbin and modeling to a specific size and shape, as shown in
FIG. 2. Wherein, the fiber elongation of the blended yarn 10 is 10%
to 25%, the fiber strength of the blended yarn is from 20 to 40
cN/tex, and the denier value of the blended yarn is from 150D to
600D.
[0047] Step 600: Weaving yarn; a recycled fabric structure 1 of the
present application may be manufactured by weaving or interlooping
the blended yarn 10 though textile techniques, and further be
utilized in various textiles such as clothing, vamps, gloves, hats,
purses and accessories.
[0048] Practically, the remaining material are collected as knitted
cloth waste, and the knitted cloth waste are cut into a
predetermined size. The cut knitted cloth waste are then applied
with a fiber opening process and cotton scutching. The knitted
cloth wastes are applied with the fiber opening process several
times in order to improve fluffiness. The first fiber 14 and the
second fiber 16 are then mixed sufficiently and evenly to produce
even cotton rolls or cotton layers. A cotton carding process is
then performed, in which the cotton rolls or the cotton layers are
carded, impurities removed, and mixed in order to produce even
cotton bars 12. Subsequently, the plurality of cotton bars 12 are
doubled and drafted, and vertically arranged and twisted with each
other in order to produce even cotton bars 12. Finally, an
alternating process and a yarn ring-spinning process are performed
to produce a blended yarn 10 having an appropriated diameter and
strength. The product blended yarn 10 may be wound on a bobbin for
ease of storage. Weaving or interlooping the produced blended yarn
10 mentioned above, will produce a recycled fabric structure of the
present application.
[0049] Specifically, a knitted cloth waste being dyed may be
recycled. The yarn of such type of knitted cloth has a denier value
of 75D, 150D, 300D or 600D, or a polyfilament yarn number of 24 f,
48 f or 72 f. The recycled fibers having different specification
mentioned above may be mixed and produce a yarn having a wire
diameter difference. For instance, the thread count of the blended
yarn forming the blended yarn is 6 s, 7 s, 8 s, 10 s, 11 s, 12 s,
15 s, or 20 s. Hence, the reason of the slub 13 formed on the
blended yarn 10 of the present application may comprises at least
one of the followings: (1) the slubs covering the recycled fiber
during twisting; (2) the wire diameter difference generated by
intercrossing of different specifications of fibers during mixing
recycled knitted clothes. The blended yarn 10 of the recycled
fabric structure 1 of the present application have such the same
physical properties as a blended yarn 10 of a normal fabric that it
is appropriate for manufacturing knitted vamp clothes. For
instance, when the blended yarn has a denier value between 150D to
600D, the fiber strength of the blended yarn 10 of a normal fabric
is from 20 to 40 cN/tex, and the elongation is 10% to 25%. The
blended yarn 10 of the recycled fabric structure 1 of the present
application is also within the above range.
[0050] Please refer to FIGS. 7A and 7B, the main structure of the
recycled fabric structure 2 of the second preferable embodiment of
the present application is mostly the same as that of the
aforementioned first embodiment. The differences between the
present embodiment and the first embodiment are: the woven fabric
is constructed by perpendicularly interlacing two or more groups of
the vertical blended yarn 10 and the horizontal blended yarn 10 is
relatively solid and stable, and has varieties of arrangement by
various patterns.
[0051] In summary, the recycled fabric structure 1 of the present
application recycles and utilizes knitted cloth waste which is
already dyed. Hence, natural, irregular colors are reused without
the requirement of an additional dye process. This may
significantly reduce environmental pollution and achieve high
efficiency for recycling and reusing of the resources, without
affecting the properties of the recycled fabric.
[0052] The above descriptions are only exemplary, and should not be
considered as limitations. It is able to make equivalent
modifications and improvement without departing from the concept of
the present disclosure, and these all belong to the appending
claims of the present disclosure.
* * * * *