U.S. patent application number 16/289543 was filed with the patent office on 2020-05-21 for yarn manufacturing.
This patent application is currently assigned to Amrapur Overseas, Inc.. The applicant listed for this patent is Amrapur Overseas, Inc.. Invention is credited to Vikas MAKKAR.
Application Number | 20200157708 16/289543 |
Document ID | / |
Family ID | 70727021 |
Filed Date | 2020-05-21 |
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United States Patent
Application |
20200157708 |
Kind Code |
A1 |
MAKKAR; Vikas |
May 21, 2020 |
YARN MANUFACTURING
Abstract
A process for manufacturing a yarn includes twisting the yarn in
a first direction for a predefined number of twists. The method
also includes, after the predefined number of twists, twisting the
yarn in a second direction for a predefined number of twists, the
predefined number of twists for the second yarn is same as the
predefined number of twists for the first yarn. The twisting of the
yarn in the second direction creates an air bed within the yarn's
fibers.
Inventors: |
MAKKAR; Vikas; (Village
Kuranwala, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amrapur Overseas, Inc. |
Corona |
CA |
US |
|
|
Assignee: |
Amrapur Overseas, Inc.
|
Family ID: |
70727021 |
Appl. No.: |
16/289543 |
Filed: |
February 28, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 1/024 20130101;
D01H 7/90 20130101; D02G 1/008 20130101; D02G 1/00 20130101; D02G
1/0206 20130101; D02G 3/286 20130101 |
International
Class: |
D02G 1/02 20060101
D02G001/02; D02G 3/28 20060101 D02G003/28; D01H 7/90 20060101
D01H007/90; D01H 1/11 20060101 D01H001/11; D01H 7/92 20060101
D01H007/92 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 20, 2018 |
IN |
201841043600 |
Claims
1. A process for manufacturing a yarn, comprising: twisting a
plurality of fibers in a first direction; and twisting the
plurality of fibers in the second direction, wherein a change of
twisting from the first direction to the second direction or vice
versa creates an air gap between the plurality of fibers, and the
air gap is configured to provide the effect of a thicker yarn upon
completion of manufacturing.
2. The process of claim 1, wherein the twisting of the plurality of
fibers in the first direction is for a predefined number of
twists.
3. The process of claim 2, wherein the twisting of the plurality of
fibers in the second direction is for a predefined number of
twists, the predefined number of twists in the second direction
being same as the predefined number of twists in the first
direction.
4. The process of claim 1, wherein the twisting of the plurality of
fibers in the first direction is based on a twist per meter.
5. The process of claim 4, wherein the twisting of the plurality of
fibers in the second direction is based on a twist per meter, the
twist per meter in the second direction being the same as the twist
per meter of the first direction.
6. The process of claim 1, wherein the twisting of the plurality of
fibers in the first direction is in a `S` direction or `Z`
direction.
7. The process of claim 1, wherein the twisting of the plurality of
fibers in the second direction is in a direction opposite to the
twisting of the plurality of the fibers in the first direction.
8. A process for manufacturing a yarn, comprising: twisting the
yarn in a first direction for a predefined number of twists or
predefined number of time; after the predefined number of twists or
after predefined number of time, twisting the yarn in a second
direction for a predefined number of twists or predefined number of
time, the predefined number of twists or the predefined number of
time for the second yarn is same as the predefined number of twists
or the predefined number of time for the first yarn, wherein the
twisting of the yarn in the second direction creates an air bed
within the yarn's fibers.
9. The process of claim 8, further comprising: alternating twisting
of the fibers of the yarn between the first direction and the
second direction to trap air within the fibers.
10. The process of claim 9, wherein the trapping of the air results
in an expansion of the yarn.
Description
FIELD
[0001] The present invention relates to manufacturing yarn, and
more particularly, to a process for manufacturing yarn.
BACKGROUND
[0002] With conventional yarn manufacturing, yarn 100 undergoes
either a "S" twist 102 or a "Z" twist 104. See, for example, FIG.
1. For example, the difference between the two is the direction in
which the fibers are twisted as the thread is spun: S twist is to
the right and Z twist is to the left.
SUMMARY
[0003] Certain embodiments of the present invention may provide
solutions to the problems and needs in the art that have not yet
been fully identified, appreciated, or solved by current yarn
manufacturing techniques. For example, some embodiments generally
pertain to a process for manufacturing yarn using both a "S" twist
and "Z" twist, one-by-one under a controlled environment.
[0004] In an embodiment, a process for manufacturing a yarn
includes twisting a plurality of fibers in a first direction. The
process also includes twisting the plurality of fibers in the
second direction. The change of twisting from the first direction
to the second direction or vice versa creates an air gap between
the plurality of fibers. The air gap is configured to provide the
effect of a thicker yarn upon completion of manufacturing.
[0005] In another embodiment, a process for manufacturing a yarn
includes twisting the yarn in a first direction for a predefined
number of twists or for a predefined period of time. The process
also includes twisting the yarn in a second direction for a
predefined number of twists or for a predefined number of time. The
predefined number of twists and the predefined number of time for
the second yarn is same as the predefined number of twists or the
predefined number of time for the first yarn. The twisting of the
yarn in the second direction creates an air bed within the yarn's
fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In order that the advantages of certain embodiments of the
invention will be readily understood, a more particular description
of the invention briefly described above will be rendered by
reference to specific embodiments that are illustrated in the
appended drawings. While it should be understood that these
drawings depict only typical embodiments of the invention and are
not therefore to be considered to be limiting of its scope, the
invention will be described and explained with additional
specificity and detail through the use of the accompanying
drawings, in which:
[0007] FIG. 1 is a diagram illustrating a yarn undergoing a "S"
twist and a "Z" twist, according to an embodiment of the present
invention.
[0008] FIG. 2 is a diagram illustrating a yarn having an alpha
angle and a manufactured yarn having a new alpha angle, according
to an embodiment of the present invention.
[0009] FIG. 3 is a diagram illustrating a yarn, according to an
embodiment of the present invention.
[0010] FIG. 4 is a flow diagram illustrating a process for
manufacturing the yarn, according to an embodiment of the present
invention.
[0011] FIG. 5, which is a diagram of a yarn with an air gap created
by the change in twist direction, according to an embodiment of the
present invention.
[0012] FIG. 6 is a diagram illustrating a comparison of twisted
yarn fibers and angles, according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] Some embodiments generally pertain to manufacturing yarn. In
an embodiment, the yarn is processed with both "S" and "Z" twists,
one-by-one simultaneously under a controlled environment.
Controlled environment may refer to the spindle speed at which the
twisting is performed, for example. In some embodiments, the
twisting is performed at a rate of 1,200 to 12,500 RPM. This
creates an air bed between the fibers. The air bed essentially
expands the yarn to form an airy and bulkier yarn.
[0014] FIG. 2 is a diagram illustrating a yarn 200A having an alpha
angle and a manufactured yarn 200B having a new alpha angle,
according to an embodiment of the present invention. A yarn may be
composed of a plurality of fibers. In an embodiment, yarn 200 may
have an alpha angle. It should be noted that the unit for twist is
different in the above expressions of the twist factor.
Furthermore, the twist factor may be known as twist multiplier,
twist alpha, or twist coefficient.
Angle of Twist (Alpha)
[0015] In an embodiment, the yarn twist angle is the angle between
a tangent to the helix formed by a fiber on the yarn surface and
the yarn axis. If the twist multiplier of a cotton yarn is known,
the twist angle can be easily calculated.
Factors Affecting Twist
[0016] The twist introduced in the yarn during spinning may depend
upon several factors. These factors include, but are not limited
to, the count of the yarn to be spun, the quality of the cotton,
the fineness of the fiber being spun, and the softness of the
fabric into which the yarn is to be converted.
[0017] During the manufacturing process, yarn 200A undergoes an
alternating "S" and "Z" twists. This alternating "S" and "Z" twist
traps air within (or between) the fiber (e.g., cotton fiber). The
trapped air creates a gap between the fiber, resulting in the
expansion of the fiber (see yarn 200B).
[0018] With this two-for-one process (e.g., the alternating "S" and
"Z" twists), yarn 200B is free from imperfections. For example,
yarn imperfections are generally measured using an imperfection
index (IPI). For a basic ring spun yarn, the IPI has a carded
quality yarn of less than equal to (.ltoreq.) 200 and a combed
quality of less than equal to (.ltoreq.) 20. With the two-for-one
process, the IPI is approximately 7 in certain embodiments. In
other words, this alternating two-for-one process gives a higher
level of consistency and a better end product from all
prospects--bulk, feel, and aesthetics.
[0019] FIG. 3 is a diagram illustrating a yarn 300, according to an
embodiment of the present invention. In an embodiment, a yarn may
be composed of a plurality of fibers. In FIG. 3, for example, yarn
is composed of two fibers F1, F2. Fibers F1, F2 are twisted in a
"S" (see S-Ply Twist 302) twist, e.g., fibers F1 and F2 are twisted
in a first direction. After a predefined number of twists in the
first direction, fibers F1 and F2 are subsequently twisted in a "Z"
(see Z-Ply Twist 304) twist, e.g., fibers F1 and F2 are twisted in
a second direction. The change in the twist direction from the
S-Ply Twist 302 to the Z-Ply twist 304 produces an air bed 306
between fibers F1, F2. Similar, the change in the twist direction
from the Z-Ply Twist 304 and the S-Ply Twist 302 produces an air
bed 306. See FIG. 5, which is a diagram of a yarn 500 with an air
gap 502 created by the change in twist direction, according to an
embodiment of the present invention. The twisting techniques may
create air gaps. In other words, the air gaps may be referred to as
the micro distance created between the fibers as shown in items 505
and 506 of FIG. 5.
[0020] Below is a general guideline for manufacturing the yarn.
Blow Room
[0021] In an embodiment, blow room is the initial stage in the
spinning process. The name blow room is given because of "air flow"
and all processes are performed in the blow room because of the air
flow.
[0022] Blow room may include different machines to carry out the
objectives therein. In blow room, the tuft size of cotton becomes
smaller and smaller. Put simply, a section in which the supplied
compressed bales are opened, cleaned and blended or mixed to form.
uniform lap of specific length. This may be referred to as blow
room section. It should be appreciated that during the opening,
cleaning, blending, or mixing, different faults or defects may
occur in the blow room. Also, in the blow room, normally 40-70
percent trash is removed.
Carding
[0023] Carding is a mechanical process that disentangles, cleans
and intermixes fibers to produce a continuous web or sliver
suitable for subsequent processing. In this process, fibers are
opened and parallelized to remove dust, impurities, and short
fibers. This produces a continuous strand of sliver. This is
achieved by passing the fibers between differentially moving
surfaces covered with card clothing, for example.
Unilap
[0024] In an embodiment, prior to combing, a lap of desired
fineness, length, weight, and fiber orientation is fed to the
comber for an effective combing process.>
Drawframe
[0025] In an embodiment, draw frame machine for spinning is used to
transform the sliver from the carding into a drawn sliver in cotton
spinning mill. The draw frame improves the uniformity of the fibers
by drafting and doubling and straightens the crimped, curled and
hooked fibers. The operation of draw frame is blended, doubled and
leveled.
Combing
[0026] A comber machine may comb the fiber. It should be noted that
the straightening and parallelization of fibers and the removal of
short fibers and impurities may be accomplished by using combs,
knives, brushes and rollers.
Drawframe
[0027] After combing, the fiber may be spun through the draw frame
machine again. A detailed explanation of the draw frame machine is
explained above.
Spedframe
[0028] With the sped frame, the draw sliver is attenuated to a
suitable size for spinning by inserting a small amount of twist for
strengthening the roving and by winding the twisted strand roving
into a bobbin.
Ringframe
[0029] This process further drawings out roving to the final yarn
count needed. For example, a twist is inserted into to the fibers
by way of a rotating spindle and winding the yarn on a bobbin. A
stationary ring is around the spindle, which holds the
traveler.
Autoconer
[0030] The autoconer machine is used in the winding process to
obtain a high quality yarn with low man power. For example, threads
are spliced automatically. That is, the threads are opened at the
broken ends and the ends are retwisted after the removal of
faults.
[0031] After autoconing, the yarn is put on a two-for-one twisting
machine, and the yarn undergoes a simultaneous "S" and "Z" twist,
resulting in an "air-bed" layered yarn.
[0032] FIG. 4 is a flow diagram illustrating a process 400 for
manufacturing the yarn, according to an embodiment of the present
invention. In an embodiment, process 400 may begin at 402 with
twisting the yarn's fibers in a `S` or `Z` direction; otherwise
known as a first direction. In an embodiment, the twisting of the
fibers in the first direction may be for a predefined number of
twists. In other embodiments, however, twisting in either direction
is simultaneous and is based on time and speed. A formula that may
be used to calculate the twist per meter (TPM) is=Spindle
Speed/Delivery Speed, e.g., rotations per minute (RPM) divided by
meters per minute.
[0033] At 404, the yarn's fibers are twisted in a second (or
opposite) direction. The second direction may be either a `Z` or
`S` direction, essentially being in the opposite direction to that
of the first direction. The number of twists, or the timing of the
twists, in the second direction may be the same as the first
direction. By quickly changing the direction of the twist, an
"air-bed" layered yarn is developed.
[0034] At 406, if the manufacturing of the yarn is complete, then
process 400 is completed; otherwise, process 400 returns to step
402. Once the desired count of yarn is achieved, i.e., yarn mass or
liner mass density which is measured in Tex-English yarn count
system, the yarn mass or linear mass is calculated by below
formula
n F = tex yarn tex fiber ##EQU00001## to give ##EQU00001.2## tex
yarn = n F .times. tex fiber ##EQU00001.3##
[0035] Where n.sub.F is the number of fibers.
[0036] Is should be noted that the number of fibers depends on yarn
type. In certain embodiments, for some types of yarns, 30 to 33
fibers are twisted.
[0037] In some embodiments, the process is carried out on coarse
counts, e.g., yarns that have counts 13's and below. The primary
use of this yarn may be in products that use coarse counts, such as
terry towels, rugs, and bathmats. As discussed, the yarn is bulkier
than other conventional yarns, which have been made using the same
yarn count. For example, a 550 GSM towel made of 9's carded ring
spun yarn would be at least 15 percent to 20 percent less bulky
than towels made under the embodiments described herein.
[0038] The absorbency of the product made using the process
described herein is reasonably higher than the conventional yarn
towels. The quality of towels made from this yarn can be referred
or compared to Zero-Twist towels. However, the advantages of the
towels in some of these embodiments are that the yarn is processed
without using any PVA (Poly Vinyl Alcohol), which is a threat to
the environment. Another advantage is that towels made of this yarn
are quite low on lint.
[0039] In the above described process, where a twist in a first
direction results in the yam being Z twisted then the twist in the
second direction is in an S direction and effectively untwisting
the yarn. In some embodiments, the amount of twist and untwist, or
counter twist remains balanced to ensure that torque created by Z
twisting and remaining in the yarn is balanced by torque created by
S twisting to for a balanced yarn. It follows, that the degree of
the first and second twisting, and the respective directions of
same, will vary according to the nature of yarn to be twisted but
in any event will produce a balanced yarn. Fabrics produced from
yarns treated as per the above method typically exhibit no, or at
least very little, spirality before and after processing--which
results in soft and bulky, as well as a smoother fabric.
[0040] FIG. 6 are charts 600A and 600B illustrating a comparison of
twisted yarn fibers and angles, according to an embodiment of the
present invention. The angle between consecutive fibers in a spun
yarn is directly proportional to the structure and tightness of the
yarn and inversely proportional to the softness and airiness of the
resultant yarn. Simply put, charts 600A and 600B show the fiber
extensions in a yarn, which can otherwise only be measured with
great difficulty. Such a scale could, however, probably be provided
by an angle, for example, the angle .gamma. of inclination to the
axis. Greater the angle lesser is the strength and higher is the
softness and bulk and Vice Versa.
[0041] Unlike the conventional method used for yarn spinning, which
is to either undergo a S or Z twist, with some of the embodiments
described herein the twisting direction of the yarn affects the
final properties of the fabric. Further, the combined use of the
two twist directions nullifies skewing in final fabric making the
fabric not only fluffier and softer, but also bulkier. This is
primarily due to the "airy beds" as referred or reduction of
"spirality effect" created between the fibers.
[0042] Also, in some embodiments, the yam is free of distorting
forces, achieving a permanent twist setting. This also results in
the woven fabric being free of spirality. Further, the yarn, and
consequently, the woven fabric is bulkier, fuller, and has a better
handle than that given by a twistless yarn.
[0043] It will be readily understood that the components of various
embodiments of the present invention, as generally described and
illustrated in the figures herein, may be arranged and designed in
a wide variety of different configurations. Thus, the detailed
description of the embodiments, as represented in the attached
figures, is not intended to limit the scope of the invention as
claimed, but is merely representative of selected embodiments of
the invention.
[0044] The features, structures, or characteristics of the
invention described throughout this specification may be combined
in any suitable manner in one or more embodiments. For example,
reference throughout this specification to "certain embodiments,"
"some embodiments," or similar language means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
present invention. Thus, appearances of the phrases "in certain
embodiments," "in some embodiment," "in other embodiments," or
similar language throughout this specification do not necessarily
all refer to the same group of embodiments and the described
features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments.
[0045] It should be noted that reference throughout this
specification to features, advantages, or similar language does not
imply that all of the features and advantages that may be realized
with the present invention should be or are in any single
embodiment of the invention. Rather, language referring to the
features and advantages is understood to mean that a specific
feature, advantage, or characteristic described in connection with
an embodiment is included in at least one embodiment of the present
invention. Thus, discussion of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0046] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize that the invention can be practiced without one or
more of the specific features or advantages of a particular
embodiment. In other instances, additional features and advantages
may be recognized in certain embodiments that may not be present in
all embodiments of the invention.
[0047] One having ordinary skill in the art will readily understand
that the invention as discussed above may be practiced with steps
in a different order, and/or with hardware elements in
configurations which are different than those which are disclosed.
Therefore, although the invention has been described based upon
these preferred embodiments, it would be apparent to those of skill
in the art that certain modifications, variations, and alternative
constructions would be apparent, while remaining within the spirit
and scope of the invention. In order to determine the metes and
bounds of the invention, therefore, reference should be made to the
appended claims.
* * * * *