Carding machine feed method for obtaining a hybrid yarn, yarn and fabric obtained therewith

Abstract

A method for manufacturing a yarn loading comb is disclosed. The method includes deriving a component loading plan having a plurality of discrete loading steps. The series of discrete loading steps includes at least a first loading amount and a second loading amount, wherein the sum of the first loading amount and the second loading amount is a first total loading amount. The method includes loading a first amount of a first component, the first amount being equal to the first loading amount of the discrete loading steps, loading a second amount of a second component, the second amount being equal to the second loading amount of the discrete loading steps, and repeating the steps of loading the first amount and loading the second amount for each of the discrete loading steps.

Description

[0001] Invention Field

[0002] This invention relates to methods for manufacturing yarns or fabrics, particularly, but not limited to, methods related to the combing process. Background of the Invention

[0004] The manufacture of yarns and fabrics made from such yarns is known, whereby both the yarn and the fabric possess a single set of properties or characteristics along their entire length. When woven into a fabric, conventional yarns provide the resulting fabric with a consistent appearance and properties.

[0005] Typically, to change the properties of a fabric, the yarn or thread needs to be changed midway through the weaving process. However, doing so can introduce visible changes to the fabric (such as, but not limited to, changes in texture, color, or pattern), which may be undesirable.

[0006] Furthermore, fabrics are known to be made from yarns containing animal fibers and synthetic materials. The synthetic materials increase the strength of the yarn and reduce the risk of yarn damage or breakage during weaving. After the weaving process, the synthetic materials can dissolve, leaving only the animal fibers. This makes it possible to produce fabrics that are finer and lighter than those that could be made in other ways (due to the insufficient strength of unsupported yarn).

[0007] The inventors have recognized the shortcomings of existing methods. Invention Overview

[0009] According to a first aspect of the present invention, a method for loading a carding machine is provided, comprising:

[0010] The derivation includes a component loading plan comprising multiple discrete loading steps, wherein each discrete loading step includes at least a first loading amount and a second loading amount, and wherein the sum of the first loading amount and the second loading amount is a first total loading amount;

[0011] Load the first component in a first quantity, the first quantity being equal to the first loading quantity in the discrete loading step;

[0012] The second component is loaded in a second quantity, which is equal to the second loading quantity in the discrete loading step; and

[0013] For each of the multiple discrete loading steps, the steps of loading the first quantity and loading the second quantity are repeated.

[0014] The first total load can have a constant value. In some examples, both the first and second loads can be constant for each of the multiple discrete loading steps. In some examples, the first load can vary according to a predefined function between at least two of the multiple discrete loading steps. The first load can vary linearly between the first loading step and the final loading step of the multiple discrete loading steps.

[0015] Each of the multiple discrete loading steps may also include a third loading amount, and the method may further include the following steps:

[0016] Load a third component in a third quantity, the third quantity being equal to the second loading quantity in the discrete loading step; and

[0017] The repeated steps also include a step of repeatedly loading a third quantity for each of the multiple discrete loading steps.

[0018] At least one of the first or second components may include natural fiber material and sacrificial fiber material in a first mixing ratio. At least one of the first, second, or third components may include natural fiber material and sacrificial fiber material in a first mixing ratio. The first mixing ratio may be in the range of 70:30 to 30:70, optionally in the range of 65:35 to 35:65, optionally in the range of 60:40 to 40:60, optionally in the range of 55:45 to 45:55. The first mixing ratio may be 50:50.

[0019] Sacrificial fiber materials may include either water-soluble synthetic materials or cotton fiber materials.

[0020] In some examples, the steps of deriving a component loading plan may include: selecting at least a portion of a first prior component loading plan; and performing the derivation steps based at least in part on the selected portion of the first prior component loading plan.

[0021] The derivation steps may further include:

[0022] Select at least a portion of multiple prior component loading plans; and

[0023] The derivation steps are performed at least in part based on one or more of the selected parts.

[0024] According to a second aspect of the present invention, a method for forming strands is provided, the method comprising:

[0025] According to the above method, at least the first component and the second component are loaded into the carding machine;

[0026] Comb at least the first and second components to produce the first comb strip;

[0027] The comb is spun into the first strand.

[0028] The loading step may include loading at least a first component, a second component, and a third component into a carding machine according to the method described above; and the carding step may include carding at least the first component, the second component, and the third component to produce a first comb. In some examples, at least one of the first component, the second component, or the third component comprises a water-soluble synthetic material.

[0029] According to a third aspect of the invention, a strand formed by the method described above is provided.

[0030] According to a fourth aspect of the present invention, a method for forming a fabric is provided, the method comprising:

[0031] A fabric is woven from a first yarn, the first yarn comprising at least a first strand formed by the method described above.

[0032] According to a fifth aspect of the invention, a fabric formed by the method described above is provided.

[0033] According to a sixth aspect of the present invention, a method for forming a fabric is provided, the method comprising:

[0034] A fabric is woven from a first yarn, the first yarn comprising at least a first strand formed by the method described above; and

[0035] Dissolve water-soluble synthetic materials.

[0036] According to a seventh aspect of the invention, a fabric formed by the method described above is provided. Brief description of the attached diagram

[0038] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which:

[0039] Figure 1 An embodiment of the method according to the first aspect of the present invention is illustrated schematically;

[0040] Figure 2 It shows Figure 1 The method steps shown are as follows;

[0041] Figure 3 An embodiment of the method according to the second aspect of the present invention is illustrated schematically;

[0042] Figure 4 It shows Figure 3 The method steps shown are as follows;

[0043] Figure 5A first exemplary loading component plan according to one aspect of the present invention is shown;

[0044] Figure 6 A second exemplary loading component plan is shown according to one aspect of the invention;

[0045] Figure 7 A method according to a third aspect of the present invention is shown;

[0046] Figure 8 A method according to a fourth aspect of the present invention is shown;

[0047] Figure 9 The method according to the fifth aspect of the invention is shown; and

[0048] Figure 10 A method according to the sixth aspect of the present invention is shown.

[0049] Description of preferred embodiments

[0050] The carding process typically involves feeding fibers into a carding machine, where the fibers are unwound, cleaned, and mixed so that they can be spun into yarn.

[0051] Various combing processes are well known in the art and will therefore not be described in further detail. However, specific parts of the combing process may be referred to in the following necessary or relevant places.

[0052] A central aspect of the carding process is the loading step, in which fibers (or other components) are loaded into the carding machine. Typically, fibers are loaded into the carding machine in batches at specific intervals. When using only a single color, the loading frequency and amount are used to maintain a uniform amount of fiber per unit length, thereby ensuring uniform yarn thickness after spinning.

[0053] According to a first aspect of the invention, reference will now be made to Figure 1 and Figure 2 Describe the method of loading the combing machine 100.

[0054] In the first step 201, a component loading plan 102 is derived, comprising a plurality of discrete loading steps 104, wherein each of the discrete loading steps comprises a first loading amount 106 and a second loading amount 108, and wherein the sum of the first loading amount and the second loading amount is a first total loading amount 110.

[0055] Component loading plans can be derived in any suitable manner. In some examples, the component loading plan is derived based on one or more expected characteristics or properties of the resulting comb, thread, yarn, or fabric. In some examples, the component loading plan is derived based on one or more properties or characteristics of one or more of the materials used. In some examples, the component loading plan is derived based on one or more properties or characteristics of the carding machine or other machine or apparatus used in one or more of the carding process, spinning process, weaving process, or a combination of these processes.

[0056] A component loading plan may include any suitable or advantageous number of discrete loading steps. In some examples, the number of discrete loading steps may depend on the expected length of the finished yarn. The number of discrete loading steps may also depend on one or more of the following: the expected loading frequency; the expected total loading amount for each loading step; or the expected linear weight of the comb, ply, or yarn.

[0057] Unlike some conventional methods that involve the manufacture of single-component yarns and their individual processing steps, this exemplary method includes the use of a first component and a second component. This allows the use of components with different characteristics or properties. For example, characteristics or properties include (but are not limited to): material selection; material blending; color; fiber thickness; fiber length; or material elasticity.

[0058] The first and second loading amounts can have any suitable values. In known methods using a single component, the loading amount and loading frequency affect the properties of the resulting combed material (also called comb sliver), and consequently, the properties of the spun yarn or ply. Generally, it is desirable to maintain a constant total loading amount and a fixed loading frequency to ensure that the resulting yarn or ply is consistent. Specifically, it is desirable to ensure that the linear density of the resulting yarn or ply is substantially constant along its entire length.

[0059] In one example, the sum of the first and second loads in each discrete loading step is the first total load, and the first total load has a constant value. As mentioned above, this ensures that the properties or characteristics of the resulting line or strand are substantially consistent.

[0060] In some examples, the first and second loads are constant for each of the multiple discrete loading steps. In such examples, the resulting thread or yarn is a thread or yarn with a substantially constant set of characteristics over its entire length.

[0061] In some examples, the first load and the second load may vary in an appropriate manner. In a particular example, the first load and the second load are varied so that the first total load has a constant value. In other examples, the first load increases while the second load decreases by the same amount, so that the first total load always remains constant. For the sake of simplicity, and unless otherwise specified, when referring to the first load and its variations, it will be assumed that the second load varies proportionally to ensure that the first total load remains substantially constant throughout the process.

[0062] In one example, the first load amount changes according to a predefined function between at least two of a plurality of discrete loading steps. The first load amount can be changed according to any suitable function. It is understood that a particular function can be chosen based on the desired or anticipated construction of the fabric or garment ultimately manufactured by the result of this method. In some examples, the function is a monotonic function (e.g., monotonically increasing or monotonically decreasing). The function can be strictly monotonic or weakly monotonic. In other examples, the function is non-monotonic. In other examples, the function is periodic. In still other examples, the function is aperiodic. Exemplary functions include, but are not limited to: sine, parabola, logarithm, or exponential. In some examples, the change in the first and second load amounts is defined by multiple functions. In some examples, the change in load amount cannot be defined by any particular function. It is understood that the choice of function or change, and the specific parameter and variable values ​​used for such function, depends on the length of the resulting yarn and the size and expected properties of the fabric manufactured from such yarn.

[0063] In a specific example, the first load varies linearly between the first loading step and the final loading step in a plurality of discrete loading steps. The first load varies between a first value and a second value.

[0064] Any suitable first value can be used, and any suitable second value can be used. In some cases, it may be desirable or advantageous to completely convert from the first component to the second component during the process. In this case, in the first loading step of multiple discrete loading steps, the first loading amount can be substantially the same as the total loading amount (where the second loading amount is initially substantially zero). Similarly, in the final loading step of multiple discrete loading steps, the first loading amount can be substantially zero (and the second loading amount is substantially the same as the total loading amount).

[0065] If expressed as a percentage, in the first loading step of multiple discrete loading steps, the first loading amount may include 100% of the total loading amount, and the second loading amount may include 0% of the total loading amount. Similarly, in the final loading step of multiple discrete loading steps, the first loading amount may include 0% of the total loading amount, and the second loading amount may include 100% of the total loading amount.

[0066] In other cases, partial conversion between components may be desirable or advantageous. In other words, both the first and second components are used in all the multiple discrete loading steps. In one such example, in the first loading step of the multiple discrete loading steps, the first load comprises 75% of the total load, and the second load comprises 25% of the total load. In the final loading step of the multiple discrete loading steps, the first load comprises 25% of the total load, and the second load comprises 75% of the total load.

[0067] Undoubtedly, the above is purely for illustrative purposes, and the first load amount can, in principle, vary between any percentage or proportion of the total load amount. Furthermore, the first and second load amounts can vary in a non-monotonic manner. In the example above, while the first load amount varies between 75% and 25% of the total load amount between the first discrete loading step and the final discrete loading step, for one or more intermediate discrete loading steps, the first load amount can, for example, include 100% or 0%.

[0068] In the second step 202, a certain amount of the first component 112 is loaded, which is equal to the first loading amount in the specific discrete loading step. The first component can be loaded in any suitable manner. It should be understood that many specific loading mechanisms or methods are conceivable within the scope of this disclosure. In some examples, the loading mechanism automatically loads an appropriate amount of material during the discrete loading step. The loaded material can be provided, for example, from a storage element or unit connected to the loading mechanism.

[0069] The first component can include any suitable material or mixture of materials. In some examples, the first component includes natural fibers or a mixture of multiple types of natural fibers. In some examples, the first component includes sacrificial fiber material. In one example, the first component includes a mixture of natural fibers (or multiple types of natural fibers) and sacrificial fiber material. An example of this will be discussed in more detail below.

[0070] In the third step 203, a certain amount of the second component 114 is loaded, which is equal to the second loading amount in the specific discrete loading step. Similar to the first component, the second component can be loaded in any suitable manner. It should be understood that many specific loading mechanisms or methods are conceivable within the scope of this disclosure. In one example, the second component is loaded in the same manner as the first component.

[0071] The second component can include any suitable material or mixture of materials. In some examples, the second component includes natural fibers or a mixture of multiple types of natural fibers. In some examples, the second component includes sacrificial fiber materials. In one example, the second component includes a mixture of natural fibers (or multiple types of natural fibers) and sacrificial fiber materials. An example of this will be discussed in more detail below.

[0072] In step 204, the steps of loading the first quantity and loading the second quantity are repeated for each of the multiple discrete loading steps. Typically, the above steps will be repeated a number of times corresponding to the number of discrete loading steps in the multiple discrete loading steps.

[0073] As described above, a component loading plan may include any appropriate number of discrete loading steps. The specific number of loading steps may depend on one or more of the following: one or more expected parameters or characteristics of the intended final product; the loading frequency; or the total loading amount. Some or all of these parameters or characteristics may be functionally interrelated and / or dependent on one or more of the other parameters or characteristics. For example, it is understood that by appropriately varying the total loading amount, a specific linear weight of the resulting comb can be achieved using multiple loading frequencies.

[0074] Typically, the total load will be constant for each of the multiple discrete loading steps. However, in some examples, the total load is variable.

[0075] As described above, this exemplary method can be used with any combination of the first and second components. However, in some cases, adding one or more additional components (such as a third component) to the process may be useful or advantageous. Therefore, the comb will comprise three or more components, each potentially having a specific set of characteristics or properties. This can be used to create a variety of different effects or features in the comb, the resulting strands or yarns, or even in the resulting woven fabric.

[0076] According to a second aspect of the invention, reference will now be made to Figure 3 and Figure 4 An exemplary method for loading a combing machine 300 is described. For the sake of brevity and clarity, features and elements that are significantly different from the corresponding features and elements described above will be discussed in detail below.

[0077] In the first step 401, a component loading plan 302 is derived, comprising multiple discrete loading steps 304, wherein each discrete loading step comprises a first loading amount 306, a second loading amount 308, and a third loading amount 309, and wherein the sum of the first loading amount, the second loading amount, and the third loading amount is a first total loading amount 310.

[0078] Although only the first, second, and third components are described in this example, the exemplary method can, in principle, include any number of components. The specific choice of the three components is purely for illustrative purposes and to ensure clarity and conciseness in discussing this method.

[0079] In the second step 402, a certain amount of the first component 312 is loaded, which is equal to the first loading amount in the specific discrete loading step. The first component can be loaded in any suitable manner. It should be understood that many specific loading mechanisms or methods are conceivable within the scope of this disclosure. In some examples, the loading mechanism automatically loads an appropriate amount of material during the discrete loading step. The loaded material can be provided, for example, from a storage element or unit connected to the loading mechanism.

[0080] In the third step 403, a certain amount of the second component 314 is loaded, which is equal to the second loading amount in the specific discrete loading step. Similar to the first component, the second component can be loaded in any suitable manner. It should be understood that many specific loading mechanisms or methods are conceivable within the scope of this disclosure. In one example, the second component is loaded in the same manner as the first component.

[0081] In the fourth step 404, a certain amount of the third component 316 is loaded, which is equal to the third loading amount in the specific discrete loading step. Similar to the first and second components, the third component can be loaded in any suitable manner. It should be understood that many specific loading mechanisms or methods are conceivable within the scope of this disclosure. In one example, the third component is loaded in the same manner as the first and second components.

[0082] Each of the first, second, or third components may comprise any suitable material or mixture of materials. In some examples, each of the first, second, or third components comprises natural fibers or a mixture of multiple types of natural fibers. In some examples, each of the first, second, or third components comprises sacrificial fiber material. In one example, each of the first, second, or third components comprises a mixture of natural fibers (or multiple types of natural fibers) and sacrificial fiber material. An example of this will be discussed in more detail below.

[0083] In some examples, the first, second, and third components comprise substantially the same material or a mixture of materials. In other examples, at least one of the first, second, or third components comprises a material or a mixture of materials that is significantly different from at least one of the other components. In some examples, each of the first, second, and third components comprises a unique material or a mixture of materials.

[0084] In step 405, the steps of loading the first quantity, loading the second quantity, and loading the third quantity are repeated for each of the multiple discrete loading steps. Typically, the above steps will be repeated a number of times corresponding to the number of discrete loading steps in the multiple discrete loading steps.

[0085] As mentioned above, the total load is generally constant throughout the loading process. However, it should be understood that in some examples, the total load for each discrete loading step can vary according to an appropriate function or variation.

[0086] Furthermore, each component (i.e., the first component, the second component, or the third component) can be changed between the first and the last of the multiple discrete loading steps of the component loading plan derived in the first method step, according to any particular function.

[0087] The specific changes can be determined by the desired effect or characteristic in the resulting comb or woven fabric. Any suitable first, second, or third value can be used. In some examples, it may be desirable or advantageous to completely switch from the first component to the second component during the process, and subsequently completely switch from the second component to the third component.

[0088] This is Figure 5 The diagram illustrates an exemplary schematic of a component loading plan 502. In this example, the component loading plan is used in conjunction with a first component, a second component, and a third component. For purely illustrative purposes, the component loading plan includes 10 discrete loading steps.

[0089] In this example, the first load (represented by the number "1" in the exemplary load group plan) is substantially the same as the total load in the first loading step of the multiple discrete loading steps (the second and third loads are initially substantially zero). In step 5, the second load (represented by the number "2" in the exemplary load group plan) is substantially the same as the total load (the first and third loads are substantially zero). In the final loading step of the multiple discrete loading steps, namely step 10, the first and second loads are substantially zero, while the third load (represented by the number "3" in the exemplary load group plan) is substantially the same as the total load.

[0090] If expressed as a percentage, in the first loading step of multiple discrete loading steps, the first loading amount may include 100% of the total loading amount, and the second and third loading amounts may include 0% of the total loading amount. Similarly, in step 5, the second loading amount may include 100% of the total loading amount, and the first and third loading amounts may include 0% of the total loading amount. In the final loading step of multiple discrete loading steps, the first and second loading amounts may include 0% of the total loading amount, and the third loading amount may include 100% of the total loading amount.

[0091] The above example is purely illustrative and is intended only to illustrate one possible loading scheme including the first, second, and third components. As stated above, any convenient, advantageous, or otherwise relevant number of components can be used.

[0092] In some examples, for at least some discrete loading steps, all three of the first, second, and third components can exist simultaneously. Figure 6 An example illustrating this situation is provided. In this example, component loading plan 602 is used in conjunction with a first component, a second component, and a third component. For purely illustrative purposes, the component loading plan includes 14 discrete loading steps.

[0093] In this example, the first load (represented by the number "1" in the exemplary load component plan) is substantially the same as the total load in the first loading step of the multiple discrete loading steps (the second and third loads are initially substantially zero). In steps 7 and 8, the first component, the second component (represented by the number "2" in the exemplary load component plan), and the third component (represented by the number "3" in the exemplary load component plan) are all present. In this example, the second load is substantially equal to the sum of the first and third loads. In the final loading step of the multiple discrete loading steps, namely step 14, the first and second loads are substantially zero, while the third load is substantially the same as the total load.

[0094] In other examples, no single component ever comprises 100% of the total load. In other words, in any given discrete loading step, there are always at least two components. It will be understood that many variations can be conceived within the scope of this disclosure.

[0095] As described above, the first, second, or third component may comprise any suitable material or mixture of materials. In some examples, one or more components comprise natural fibers or mixtures of various types of natural fibers. In some examples, one or more components comprise synthetic fiber materials. In some examples, one or more components comprise sacrificial fiber materials. In one example, one or more components comprise a mixture of natural fibers (or various types of natural fibers) and sacrificial fiber materials.

[0096] Sometimes synthetic or sacrificial materials are used to improve one or more characteristics or properties of the final product of an exemplary process (and, by extension, to improve one or more characteristics or properties of the resulting combs, threads, yarns, or woven fabrics). In one example, synthetic materials may be used to increase the strength of a material. In other instances, sacrificial fiber materials may be used to maintain the structural integrity of a material during manufacturing. After the manufacturing process is complete, the sacrificial fiber material is removed, resulting in a fabric that is finer or lighter than that obtained by other methods.

[0097] Any suitable synthetic or sacrificial fiber material can be used. In some examples, sacrificial fiber materials include suitable water-soluble synthetic materials such as (but not limited to) PVA (polyvinyl alcohol). In some examples, synthetic materials include (but are not limited to) Kuralon K-II. TM Or Solvron TM In other examples, the sacrificial fiber material includes cotton-based fibers, which can be removed after manufacturing through a carbonization process.

[0098] Since the sacrificial fiber material will not be present in the final product, it is desirable and advantageous that the amount of sacrificial fiber material is substantially constant in each component it is blended into. Each of the first, second, or third components may have a specific blending ratio of natural fiber material to sacrificial fiber material. In some examples, each blending ratio is substantially the same. In other examples, two or more blending ratios are substantially the same and different from the remaining blending ratios. In still other examples, each blending ratio is substantially unique and different from every other blending ratio. In one specific example, at least one of the first, second, or third components includes a first blending ratio of natural fiber material and sacrificial fiber material.

[0099] Each mixing ratio can have any suitable range. In some examples, the mixing ratio is in the range of 70:30 to 30:70, optionally in the range of 65:35 to 35:65, optionally in the range of 60:40 to 40:60, and optionally in the range of 55:45 to 45:55. In one example, the first mixing ratio is 50:50.

[0100] In the preceding examples, numerous method steps were described that illustrate the procedures for loading a carding machine to produce slivers. It will be understood that this exemplary method can be used alone or in combination with additional method steps, for example, as part of a larger sequence of methods. Purely by way of example, the exemplary method described above can be used as part of a ply, yarn, or fabric forming process.

[0101] As described above, the component loading plan can be derived in a suitable manner. In some examples, the component loading plan is derived based solely on one or more expected characteristics or properties of the comb, thread, yarn, or fabric obtained as described above.

[0102] In this scenario, each component loading plan is derived independently and entirely based on the initial premises or requirements. However, performing the derivation for each production batch can be time-consuming, especially when a particular component loading plan is similar to a previously derived component loading plan. For example, two subsequent production batches may differ from each other only slightly (e.g., by only a single distinct attribute or characteristic). Therefore, it may be advantageous to perform the derivation steps, at least partially, on one or more archived, stored, or otherwise pre-generated component loading plans.

[0103] Exemplary implementations of such derivation steps will now be discussed according to one aspect of the invention. It will be understood that this is purely for illustrative purposes, and other specific exemplary implementations may be contemplated within the scope of this disclosure.

[0104] In this example, at least a portion of the first previously derived component loading plan is selected. This portion can be selected in any suitable manner based on any suitable criteria.

[0105] In some examples, the selection step is performed based on the similarity between the previous component loading plan and the expected component loading plan. Similarity can be assessed using any of many methods. For example, it could be based on the use of similar quantities of components, or on the similarity between one or more expected characteristics or parameters of the product (e.g., comb, ply, yarn, or fabric) produced using the previous component loading plan and the expected characteristics of the new expected product.

[0106] In some examples, the selection process may include sub-steps that select one or more specific evaluation criteria. This may be relevant if there are specific requirements that should take precedence over other requirements. For example, in some cases, a given product may need to have certain linear density, tensile strength, color gradient, or material composition (or any other suitable or relevant parameters). It is possible to check whether the previous component loading plan is compatible with the relevant criteria and priorities.

[0107] In the second step, the derivation steps are performed at least in part based on selected portions of the previously derived component loading plan. The derivation steps can be performed in an appropriate manner and using appropriate derivation procedures or methods. This includes, but is not limited to: reusing selected portions of the previously derived component loading plan; or modifying selected portions of the previously derived component loading plan.

[0108] For example, if a selected portion is found to have a particular advantage or benefit, it is possible to reuse that portion of a previously derived component loading plan. Purely as an example, it might be found that a specific function controlling the variation of the first and second loading amounts results in particularly beneficial, advantageous, or successful combs, threads, yarns, or fabrics.

[0109] In other cases, selected portions of a previous component loading plan may not be directly reused. However, the selected portions can be modified directly in a relevant or appropriate manner. This may be the case, for example, if the new component loading plan is a minor variation of the previous component loading plan.

[0110] In some cases, it may be that no single prior component loading plan (or a portion thereof) can be suitably used alone. However, the intended product (e.g., comb, ply, thread, yarn, or fabric) may share one or more similarities with multiple prior products. In such cases, at least a portion of the corresponding multiple prior component loading plans can be selected and used to derive the component loading plan.

[0111] In one example, the derivation step further includes: selecting at least a portion of a plurality of prior component loading plans; and performing the derivation step at least in part based on one or more of the selected portions. The selection step can be performed in any suitable manner. In some examples, it is performed essentially as described above with reference to selecting a single portion of a prior component loading plan. Similarly, the execution of the derivation step can be performed in any suitable manner, for example, essentially as described above.

[0112] As an example only, one of the previous component loading plans may utilize a first specific transition between the first and second components. For instance, another previous component loading plan may utilize a second specific transition between the second and third components. In this case, it may be advantageous or otherwise desirable to manufacture slivers, strands, yarns, or fabrics having both specific transitions. Instead of performing the derivation steps from scratch, the previously generated component loading plan can be used at least partially to form the component loading plan.

[0113] Of course, it should be understood that component loading plans can be derived based on any appropriate number of prior component loading plans, and the above examples are purely for illustrative (not limiting) purposes.

[0114] According to another aspect of the invention, reference will now be made to Figure 7 An exemplary method for forming strands is described. For the sake of brevity and clarity, features and elements that differ significantly from the corresponding features and elements described above will be discussed in detail below.

[0115] In the first step 701, at least the first component and the second component are loaded into the combing machine according to the method roughly described in the preceding example. In one example, the first component and the second component are essentially as described above. Figure 2 Loaded as described.

[0116] In the second step 702, at least the first and second components are combed to produce a first comb strip. It should be understood that many specific combing methods are conceivable within the scope of this disclosure. However, for the sake of simplicity alone, this step will not be further elaborated in this disclosure.

[0117] In the third step 703, the comb is spun into a first strand. The spinning step can be carried out in any suitable manner. It should be understood that, within the scope of this disclosure, those skilled in the art can conceive of many specific methods for spinning strands, and these methods will not be reproduced in detail herein.

[0118] The first strand can then be used to weave fabrics, or it can be combined with other strands to make yarn, which can then be used to weave fabrics.

[0119] According to another aspect of the invention, reference will now be made to Figure 8 An exemplary method for forming strands is described. For the sake of brevity and clarity, features and elements that differ significantly from the corresponding features and elements described above will be discussed in detail below.

[0120] In the first step 801, based on at least one of the general descriptions in the above examples (e.g., referring to the above...), Figure 3 and Figure 4 (Generally described) The method involves loading at least the first component, the second component, and the third component into the carding machine.

[0121] As described above, the first, second, and third components can comprise any suitable materials. In one example, at least one of the first, second, or third components comprises natural fibrous materials and water-soluble synthetic materials (e.g., as referenced above). Figure 3 and Figure 4 (as described).

[0122] In the second step 802, at least the first component, the second component, and the third component are combed to produce a first comb strip. It should be understood that many specific combing methods are conceivable within the scope of this disclosure.

[0123] In the third step 803, the comb is spun into a first strand. The spinning step can be carried out in any suitable manner. It should be understood that there are many specific methods known to those skilled in the art for spinning strands, which will not be reproduced in detail here.

[0124] The first strand can then be used to weave fabrics, or it can be combined with other strands to make yarn, which can then be used to weave fabrics.

[0125] According to another aspect of the invention, reference will now be made to Figure 9 An exemplary method of fabric formation is described. For the sake of brevity and clarity, only features and elements that differ significantly from the corresponding features and elements described above will be discussed in detail below.

[0126] In the first step 901, at least a first yarn is provided, the first yarn comprising at least a first strand formed by the method described above. In one example, the first strand is formed by referring to the above... Figure 5 The methods described are essentially the same as those used in this study.

[0127] In the second step 902, a fabric is woven from at least the first yarn. The fabric can be woven in any suitable manner using a suitable loom or other similar equipment.

[0128] According to another aspect of the invention, reference will now be made to Figure 10 An exemplary fabric forming method is described. For the sake of brevity and clarity, only features and elements that differ significantly from the corresponding features and elements described above will be discussed in detail below.

[0129] In the first step 1001, at least a first yarn is provided, the first yarn comprising at least a first strand formed by the method described above. In one example, the first strand is formed by referring to the above... Figure 6 The methods described are essentially the same as those used in this study.

[0130] In the second step 1002, a fabric is woven from at least the first yarn. The fabric can be woven in any suitable manner using a suitable loom or other similar equipment.

[0131] In one example, the first yarn comprises at least a first strand, wherein the first strand comprises a first component, a second component, and a third component. In this specific example, the third component comprises a water-soluble synthetic material. Any suitable synthetic material can be used. In some examples, the third component comprises a suitable water-soluble synthetic material, such as (but not limited to) PVA (polyvinyl alcohol). In some examples, the synthetic material includes (but is not limited to) Kuralon K-II. TM Or Solvron TM .

[0132] In the third step 1003, the water-soluble synthetic material is dissolved. This step can be performed in any suitable manner. We will recognize that many specific dissolution steps may be possible within the scope of this disclosure. In particular, it should be understood that the specific nature of the dissolution step may depend on the specific characteristics or properties of the water-soluble synthetic material.

[0133] The above description is intended to be illustrative and not restrictive. Therefore, it will be apparent to those skilled in the art that modifications can be made to the invention as described without departing from the scope of the claims set forth below.

Claims

1. A method for forming a fabric or garment, comprising the following steps: (i) Derive a component loading plan based on one or more expected characteristics or properties of the desired fabric, the component loading plan including: (a) A plurality of discrete loading steps, wherein each of the discrete loading steps includes at least a first loading amount and a second loading amount, and wherein the sum of the first loading amount and the second loading amount is a first total loading amount; (b) A predefined function, wherein for at least two of the plurality of discrete loading steps, the first loading amount and the second loading amount vary according to the predefined function, wherein the predefined function is selected according to the expected construction, size and properties of the fabric or garment to be manufactured by the method; The carding machine (100) is then loaded for subsequent yarn production, the loading including: (ii) Loading a first quantity of a first component, the first quantity being equal to the first loading quantity of the discrete loading step; (iii) Loading a second quantity of the second component, the second quantity being equal to the second loading quantity of the discrete loading step; and (iv) For each of the plurality of discrete loading steps, the steps of repeatedly loading the first quantity and loading the second quantity, (v) wherein the first loading amount varies between at least two discrete loading steps in the plurality of discrete loading steps according to a predefined function in the derived component loading plan; The yarn produced is then used to manufacture fabrics or garments.

2. The method of claim 1, wherein, The first total load has a constant value.

3. The method of claim 1, wherein, The first loading amount changes linearly between the first loading step and the final loading step in the plurality of discrete loading steps.

4. The method of any one of claims 1 to 3, wherein, Each of the plurality of discrete loading steps further includes a third loading amount, and the method further includes the following steps: Load a third component in a third quantity, the third quantity being equal to the second loading quantity in the discrete loading step; and The repeated steps further include a step of repeatedly loading a third quantity for each of the plurality of discrete loading steps.

5. The method of any one of claims 1 to 3, wherein, At least one of the first component or the second component includes a first mixing ratio of natural fiber material and sacrificial fiber material.

6. The method of claim 4, wherein, At least one of the first component, the second component, or the third component comprises a first mixing ratio of natural fiber material and sacrificial fiber material.

7. The method of claim 5, wherein, The first mixing ratio is in the range of 70:30 to 30:

70.

8. The method of claim 5, wherein, The first mixing ratio is in the range of 65:35 to 35:

65.

9. The method of claim 5, wherein, The first mixing ratio is in the range of 60:40 to 40:

60.

10. The method of claim 5, wherein, The first mixing ratio is in the range of 55:45 to 45:

55.

11. The method of claim 7, wherein, The first mixing ratio is 50:

50.

12. The method of claim 5, wherein, The sacrificial fiber material includes either a water-soluble synthetic material or a cotton fiber material.

13. The method of claim 1, wherein, The steps for deriving the component loading plan include Select at least a portion of the first prior component loading plan; and The derivation steps are performed at least in part based on a selection of the first prior component loading plan.

14. The method of claim 13, further comprising: Select at least a portion of multiple prior component loading plans; and The derivation steps are performed at least in part based on one or more of the selected portions.

15. A method for forming a strand, the method include: According to the method of claim 1, at least the first component and the second component are loaded into the carding machine; Combing the at least first and second components to produce a first comb; The comb is spun into a first strand.

16. The method of claim 15, wherein, At least one of the first component and the second component includes a water-soluble synthetic material.

17. A strand formed by the method according to claim 15.

18. A method for forming a fabric, the method comprising: A fabric is woven from a first yarn, the first yarn comprising at least a first strand formed by the method according to claim 12.

19. A fabric formed by the method according to claim 18.

20. A method for forming a fabric, the method comprising: A fabric is woven from a first yarn, the first yarn comprising at least a first strand formed by the method according to claim 16; and Dissolve the water-soluble synthetic material.

21. A fabric formed by the method according to claim 20.

22. A fabric formed by the method according to claim 1.

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