Spinning process of waterless colored heather yarns

Abstract

A method of forming a colored heather yarn, comprising the sequential steps: (a) processing a natural fiber; (b) obtaining a regenerated cellulose man-made fiber; (c) producing a waterless dope-dyed man-made fiber; (d) blending the individual fibers from steps (a)-(c) to produce a blended composite of fibers; and (e) roving, spinning and winding the blended composite of fibers of step (d) into a final colored heather yarn; wherein the colored heather yarn comprises a predetermined fiber content ratio. There is also provided a colored heather yarn made according to the foregoing method.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application is a continuation-in-part of U.S. patent application Ser. No. 15 / 389,643 filed on Dec. 23, 2016, the disclosure of which is herein incorporated by reference in its entirety.TECHNICAL FIELD[0002]The present invention generally relates to a method of forming a colored heather yarn. The present invention also relates to the colored heather yarn made according to the method as defined herein.BACKGROUND OF THE DISCLOSURE[0003]Textile manufacturing is one of the oldest human activities that have evolved throughout the years. It is considered as one of the major industries that have attracted abundance of attention. It is based on the conversion of different types of fiber into different types of yarn and then yarns into their respective types of fabric. In this regard, textile manufacturing includes several processes such as cultivating and harvesting, preparatory processes, spinning processes, weaving or knitting and finally fi...

AI Technical Summary

Benefits of technology

[0011]Advantageously, the above method may result in the formation of colored heather yarn with improved quality and enhanced yarn strength. The colored heather yarn may be benzoyl peroxide safe. The colored heather yarn may also contain enhanced color effects with an enriched heather appearance under the same fiber content ratio.

Problems solved by technology

Among the industrial methods used, there are certain processes that require high consumption of energy in the form of water and electricity, especially in processes like washing, de-sizing, bleaching, rinsing, dyeing, spinning, printing, coating and finishing.

These processes are still not as environmental friendly as they should be.

These two processes require high consumption of water due to the nature of their methods.

Furthermore, during the preparatory processes such as carding, combing and / or drawing, the processes would cause the fibers to break easily, thus generating high fiber wastage.

In addition, some of the dyeing processes also lack fastness properties, leading to demand that a more efficient and energy-saving method be developed to overcome these disadvantages.

However, a melt spinning step has limitations such as an inadequate range of colored polyester chips.

Although rotor and air-jet spinning methods have higher production rates than ring spinning, the rotor spun yarns and air jet yarns are weaker and have a harsher feel than ring spun yarns.

Further, ring spinning has a higher production cost due to its additional processes than rotor and air-jet spinning.

Advantageously, the above method may result in the formation of colored heather yarn with bleachable performance that does not utilize any water during the bleaching and / or dyeing process.

The above method may also be cost efficient and may not utilize any amount of water such that the above method does not produce effluent discharge and is sustainable and eco-friendly.

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