Ultra-light yarn and preparation method thereof

Abstract

The invention provides an ultra-light yarn and a preparation method thereof, and aims to solve the problems that an existing monofilament is poor in practicability, high in material cost and prone to deformation, I-shaped PET fibers serve as raw materials, the ultra-light yarn is prepared through a specific spinneret orifice and a process, the monofilament is composed of a first transverse line part, a vertical line part and a second transverse line part, and the I-shaped monofilaments are combined together in a staggered mode. Different parameters are designed for the length, the width and the fillet of each section, and the fiber is ultralight and the performance is improved by controlling the included angle distribution of the I-shaped spinneret orifices and optimizing the parameters of the spinneret plate; the H-shaped design disperses stress, heat treatment optimizes performance, concentric circle spinneret orifice distribution guarantees quality, on the premise that the strength, elasticity and other performance of the fiber are guaranteed, light weight and multifunctionality are achieved, and remarkable economic benefits and wide market prospects are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of polyester fibers, in particular to an ultralight yarn and a preparation method thereof. Background Art

[0002] With the development of the textile industry, the performance requirements for fibers are becoming increasingly higher. Fibers produced by traditional yarn methods are gradually unable to meet market demand in terms of structure and weight. The invention with authorization announcement number CN111005140B discloses a "method for preparing seersucker," which prepares fibers from PET using the POY process, uses annular air cooling, and controls the arrangement of the spinneret holes on the spinneret to meet the requirements that "all spinneret holes are distributed in concentric circles. A three-dimensional curly polyester low-stretch yarn is produced through a specific crescent-shaped and I-shaped spinneret hole distribution, which improves the fullness and freshness of the seersucker. However, the monofilament of this invention is too heavy and feels hard, making it inconvenient to use.

[0003] The invention with authorization announcement number CN111118629B discloses a "hygroscopic antibacterial knitted fabric and its preparation method". The hygroscopic antibacterial knitted fabric is prepared using cotton fiber, blended yarn and fine denier I-shaped PET fiber as raw materials. The blended yarn is extruded on the same spinneret, and the PTT melt is divided into two paths: one path is directly extruded after distribution, and the other path is distributed together with the PBT melt in a parallel composite yarn manner and then extruded. The curling direction of the single yarn of the blended yarn in the obtained hygroscopic antibacterial knitted fabric is randomly distributed, which solves the problem of "uneven strip shape". However, the material cost of this invention is high and it is difficult to apply on a large scale.

[0004] In summary, existing yarns generally have the following disadvantages: 1) Poor practicality: Traditional fibers use a solid round hole structure, and the single fiber is too heavy and feels hard, making it inconvenient to use; 2) High material cost: To improve fiber properties, traditional yarns use a variety of composite materials or special fibers. These materials are expensive, increasing production costs and limiting their large-scale application. 3) Easy to deform: Existing hollow yarns are easily flattened during the texturizing process. Since the cross-sectional shape design of these yarns fails to fully consider the stress conditions during texturizing, the internal structure of the fibers is prone to irreversible deformation, which in turn affects the appearance and feel of the fabric. Summary of the Invention

[0005] The purpose of the present invention is to solve the problems in the prior art and to propose an ultra-light yarn and a preparation method thereof, which can solve the problems of poor practicality, high material cost and easy deformation.

[0006] To achieve the above-mentioned purpose, the present invention proposes an ultra-light yarn and a preparation method thereof, which is composed of a plurality of monofilaments with an I-shaped cross-section, wherein adjacent monofilaments are interlaced and compounded, and the I-shape includes a first horizontal line portion, a vertical line portion, and a second horizontal line portion. The first horizontal line portion is parallel to the second horizontal line portion, and the vertical line portion is not parallel to the first horizontal line portion. One end of the vertical line portion is connected to the first horizontal line portion, and the other end of the vertical line portion is connected to the second horizontal line portion. The first horizontal line portion and the second horizontal line portion of adjacent monofilaments are interlaced and compounded.

[0007] Preferably, both ends of the first horizontal line portion are semicircles, the semicircles are semicircles of a standard circle, the center of the semicircle is located on the central axis of the first horizontal line portion, the diameter of the semicircle is equal to the width of the first horizontal line portion, and the ratio of the width of the first horizontal line portion to the radius of the semicircle is 1 to 3:1.

[0008] Preferably, the first horizontal portion and the second horizontal portion are exactly the same in size and shape, the first horizontal portion and the vertical portion have the same width, and the angle between the vertical portion and the first horizontal portion is 80° to 120°.

[0009] Preferably, the ratio of the length of the first horizontal line portion to the vertical line portion is 1 to 2:1, and the ratio of the length to the width of the first horizontal line portion is 9 to 11:1.

[0010] Preferably, the number of monofilaments in the single yarn is 50 to 288F, and the fiber thickness unit in the single yarn is 240D.

[0011] Preferably, the monofilaments are all extruded from the same spinneret in a direction parallel to the positioning groove, the spinnerets on the spinneret are all I-shaped, the spinnerets are arranged in concentric circles, and the I-shaped spinnerets are evenly distributed on each layer of the ring.

[0012] Preferably, the cross sections of the I-shaped monofilaments are subjected to different forces, the positions where the I-shaped monofilaments are subjected to different forces are different, and the shapes of the I-shaped monofilaments are not completely the same.

[0013] To achieve the above-mentioned purpose, the present invention also proposes a method for preparing ultra-light yarn. The yarn preparation process is as follows: in the process of preparing fibers from PET according to the POY process, the monofilaments are extruded on the same spinneret in a direction parallel to the positioning groove, and the arrangement of the spinneret holes on the spinneret is controlled to be distributed in concentric circles. The spinneret holes are all I-shaped spinneret holes. After melt extrusion, multiple I-shaped bundles of the same shape are formed: polyester POY pre-oriented yarns. The bundles are then subjected to a texturing process: stretching and twisting to obtain yarn.

[0014] Preferably, the spinneret adopts the outer circumference size to print the spinneret specifications, the spinneret holes are distributed in concentric circles, the I-shaped spinneret holes are evenly distributed on each layer of rings, the number of spinneret holes in each circle increases from the inside to the outside, and the edges of the spinneret holes are chamfered.

[0015] Preferably, the size of the I-shaped spinneret is as follows: the spinneret includes a horizontal portion and a vertical portion, the center line of the spinneret plate forms an angle with both ends, the edge of the spinneret has a rounded transition, and the spinneret forms an angle with the center line of the spinneret plate.

[0016] Beneficial effects of the present invention: 1) Significant ultra-light performance: By using I-shaped monofilaments that can be stretched and then twisted, the amount of material used is reduced while ensuring fiber strength and elasticity, thereby reducing fiber weight and achieving an ultra-light effect; 2) Soft, breathable, and antibacterial: By interlacing and arranging the monofilaments at 50-288F, the yarn is soft and breathable, can absorb moisture and perspiration, and feels similar to cotton, giving customers a better experience. At the same time, silver ions are added to the monofilaments to improve the antibacterial properties of the yarn. 3) Significant cost reduction: This preparation method is relatively simple and has high production efficiency, which further reduces production costs and has significant economic benefits. While ensuring fiber quality, the I-shaped design reduces material usage and simplifies the process flow, effectively reducing production costs. This allows high-quality fibers to be more widely used in the market, meeting the price and quality demands of consumers at different levels. 4) Wide range of applications: Ultra-light I-shaped fibers can be widely used in all chemical fiber textile fabrics, meeting the market demand for lightweight fibers. They are especially suitable for making light, breathable, soft-touch fabrics such as home textiles and sportswear, and have broad market application prospects.

[0017] The features and advantages of the present invention will be described in detail through embodiments with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a magnified microscopic view of a cross section of the ultralight yarn of the present invention; Figure 2 Schematic diagram of the cross-sectional structure of a monofilament in the ultralight yarn of the present invention; Figure 3 It is a schematic diagram of the spinneret structure in the method for preparing ultralight yarn of the present invention. DETAILED DESCRIPTION

[0019] Example 1: See Figures 1 to 3The present invention relates to an ultra-light yarn and a preparation method thereof, which is composed of a plurality of monofilaments with an I-shaped cross section, wherein adjacent monofilaments are interlaced and composited, and the I-shape includes a first horizontal line portion, a vertical line portion, and a second horizontal line portion, the first horizontal line portion is parallel to the second horizontal line portion, the vertical line portion is not parallel to the first horizontal line portion, one end of the vertical line portion is connected to the first horizontal line portion, and the other end of the vertical line portion is connected to the second horizontal line portion, and the first horizontal line portion and the second horizontal line portion of adjacent monofilaments are interlaced and composited; both ends of the first horizontal line portion are semicircular, and the semicircle is a semicircle of a standard circle, the center of the semicircle is located on the central axis of the first horizontal line portion, the diameter of the semicircle is equal to the width of the first horizontal line portion, and the width of the first horizontal line portion is equal to the width of the semicircle. The ratio of the radius of the first horizontal line portion and the second horizontal line portion is 1 to 3:1; the size and shape of the first horizontal line portion and the second horizontal line portion are exactly the same, the width of the first horizontal line portion and the vertical line portion is the same, the angle at the connection between the vertical line portion and the first horizontal line portion is 80º to 120º, the length ratio of the first horizontal line portion to the vertical line portion is 1 to 2:1, the length and width ratio of the first horizontal line portion is 9 to 11:1, the number of monofilaments in the single yarn is 50 to 288F, the fiber thickness unit in the single yarn is 240D, the monofilaments are all extruded on the same spinneret in a direction parallel to the positioning groove, the spinnerets on the spinneret are all I-shaped, the spinnerets are arranged in concentric circles, and the I-shaped spinnerets are evenly distributed on each layer of rings.

[0020] The yarn preparation process is as follows: in the process of preparing fibers from PET according to the POY process, the monofilaments are extruded on the same spinneret in a direction parallel to the positioning groove, and the arrangement of the spinneret holes on the spinneret is controlled to be distributed in concentric circles. The spinneret holes are all I-shaped spinnerets. After melt extrusion, multiple I-shaped yarn bundles of the same shape are formed: polyester POY pre-oriented yarns. The yarn bundles are then subjected to the texturizing process: stretching and twisting to obtain yarns. Since the monofilaments are I-shaped, they will not deform during stretching and twisting, which solves the problem that hollow yarns are easily deformed by twisting.

[0021] In this embodiment, the ratio of the length of the first horizontal line portion to the vertical line portion is 1:1, and the lengths of the first horizontal line portion, the second horizontal line portion and the vertical line portion are all 1.2 mm; the angle at the connection between the vertical line portion and the first horizontal line portion is 90°; in the design of the spinneret, it is ensured that the spinnerets are distributed in concentric circles, and a total of 3 concentric circles are designed. The innermost circle has 8 I-shaped spinnerets, and the number of spinnerets in each circle increases by 9 outward. The number of monofilaments can reach 48 to 52F, the fiber thickness unit in a single yarn is 240D, and silver ions are added to the monofilament.

[0022] In this embodiment, all parameters are in the middle value of the conventional range. The ratio of the length of the first horizontal line portion to the vertical line portion is 1:1, so that when the yarn is subjected to tension, the stress can be evenly distributed along the horizontal line portion and the vertical line portion, reducing stress concentration. The lower F number ensures the hand feel and is breathable and comfortable, thereby improving the overall strength and stability of the yarn; the concentric circle layout of the spinneret holes helps to improve the uniformity and stability of the spinneret process, making the spinneret holes more smooth during extrusion and reducing the occurrence of fiber defects; silver ions make the monofilament have better antibacterial properties. This embodiment is cost-effective and suitable for all textile processing industries, such as for making lightweight fabrics, packaging materials, etc., which can effectively reduce production costs while ensuring basic product quality.

[0023] Example 2: This embodiment is basically the same as Example 1, except that: the ratio of the length of the first horizontal line portion to the vertical line portion is 1.2:1, the length of the first horizontal line portion and the second horizontal line portion are both 1.6 mm, the length of the vertical line portion is designed to be 1.3 mm, and the spinneret is designed with a total of 4 concentric circles. The innermost circle has 6 I-shaped spinneret holes, and the number of spinneret holes increases by 8 in each circle outward, and the number of monofilaments can reach 70 to 78F.

[0024] In this embodiment, the longer vertical lines make the yarn have better mechanical properties in the longitudinal direction, the strength is improved, and it can withstand greater longitudinal tensile force. At the same time, the increase in the length of the horizontal lines also enhances the transverse connection strength. Since the lengths of the vertical and horizontal lines are both taken to the upper limit, the medium F number is more stretched in the structure, the internal stress distribution after molding is more uniform, and the product quality is more stable. It has good application prospects in some industrial lifting, transportation and other fields that need to withstand large longitudinal tensile forces, and can ensure that it still maintains good integrity and reliability when subjected to heavy objects.

[0025] Example 3: This embodiment is basically the same as Example 1, except that: the ratio of the length of the first horizontal line portion to the vertical line portion is 2:1, the length of the first horizontal line portion and the second horizontal line portion are both 1.0 mm, the length of the vertical line portion is designed to be 0.5 mm, and 5 concentric circles are designed on the spinneret. The innermost circle has 8 I-shaped spinneret holes, and the number of spinneret holes in each circle increases by about 9 outward, and the number of monofilaments can reach 138 to 144F.

[0026] The larger number of spinneret holes and the optimized distribution method in this embodiment help to improve production efficiency and ensure the uniformity and stability of the yarn; as the F number gradually increases, the fabric becomes breathable and feels softer, the debugging weight does not increase, the surface of the obtained yarn is smoother, the internal structure is denser, it has better wear resistance and corrosion resistance, can adapt to more severe working environments, and has a longer service life; it is mainly used in aerospace, high-end electronic equipment and other fields with extremely high requirements for lightweight materials, which helps to improve the performance and energy efficiency of the equipment.

[0027] Working principle: It is mainly based on the unique structural design of I-shaped monofilament and its special compounding method. The I-shaped cross-sectional shape can be stretched and twisted, and has good elasticity, so that when the monofilaments are interlaced and compounded with each other, the horizontal parts can form a closer and more uniform contact, and the force can be effectively dispersed to avoid local stress caused by excessive breakage; at the same time, the reasonable angle between the vertical and horizontal parts and the precise matching of the sizes of each part further optimize the mechanical transmission path inside the yarn and enhance the overall tensile and wear resistance of the yarn; in the preparation process, by controlling the shape, arrangement and heat treatment process of the spinneret, the quality and performance consistency of the I-shaped monofilament are ensured, 50~288F makes the fabric breathable and soft to the touch, the addition of silver ions makes the yarn have better antibacterial properties, and the weight is not increased to ensure lightness and thinness. At the same time, only 240D is actually required, which is cost-effective, so that the final ultra-light yarn can give full play to its superior performance characteristics, and achieve multifunctional properties such as softness and breathability, moisture absorption and perspiration, and significant antibacterial properties on the basis of meeting lightweight requirements.

[0028] The above-mentioned I-shaped structure can be used for polyester or nylon to achieve the effect of moisture absorption, perspiration removal and softness, and is used in high-end fabrics such as yoga clothes.

[0029] The above embodiments are intended to illustrate the present invention, not to limit the present invention. Any solution that is a simple transformation of the present invention falls within the protection scope of the present invention.

Claims

1. An ultralight yarn, characterized in that: The invention is composed of a plurality of monofilaments with an I-shaped cross section, wherein adjacent monofilaments are interlaced and compounded. The I-shape includes a first horizontal portion, a vertical portion, and a second horizontal portion. The first horizontal portion is parallel to the second horizontal portion, and the vertical portion is not parallel to the first horizontal portion. One end of the vertical portion is connected to the first horizontal portion, and the other end of the vertical portion is connected to the second horizontal portion. The first horizontal portion and the second horizontal portion of adjacent monofilaments are interlaced and compounded.

2. The ultralight yarn according to claim 1, characterized in that: Both ends of the first horizontal line portion are semicircles, and the semicircles are semicircles of a standard circle. The center of the semicircle is located on the central axis of the first horizontal line portion. The diameter of the semicircle is equal to the width of the first horizontal line portion, and the ratio of the width of the first horizontal line portion to the radius of the semicircle is 1 to 3:

1.

3. The ultralight yarn according to claim 1, characterized in that: The first horizontal line portion and the second horizontal line portion are completely identical in size and shape, the first horizontal line portion and the vertical line portion have the same width, and the angle between the vertical line portion and the first horizontal line portion is 80° to 120°.

4. The ultralight yarn according to claim 1, characterized in that: The ratio of the length of the first horizontal line portion to the vertical line portion is 1 to 2:1, and the ratio of the length to the width of the first horizontal line portion is 9 to 11:

1.

5. The ultralight yarn according to claim 1, characterized in that: The number of monofilaments in the single yarn is 50 to 288F, and the fiber thickness unit in the single yarn is 240D.

6. The ultralight yarn according to claim 1, characterized in that: The monofilaments are all extruded from the same spinneret in a direction parallel to the positioning groove, the spinneret holes on the spinneret are all I-shaped, the spinneret holes are arranged in concentric circles, and the I-shaped spinneret holes are evenly distributed on each layer of rings.

7. A method for preparing ultralight yarn, characterized in that: The yarn preparation process is as follows: in the process of preparing fibers from PET according to the POY process, the monofilaments are extruded on the same spinneret in a direction parallel to the positioning groove, and the arrangement of the spinneret holes on the spinneret is controlled to be distributed in concentric circles. The spinneret holes are all I-shaped spinnerets. After melt extrusion, multiple I-shaped bundles of the same shape are formed: polyester POY pre-oriented yarns. The bundles then undergo a texturing process: stretching and twisting to obtain yarns.

8. The method for preparing an ultralight yarn according to claim 7, wherein: The spinneret adopts the outer circumference size to print the spinneret specifications, the spinneret holes are distributed in concentric circles, the I-shaped spinneret holes are evenly distributed on each layer of rings, the number of spinneret holes in each ring increases from the inside to the outside, and the edges of the spinneret holes are provided with chamfers.

9. A method for preparing an ultralight yarn according to any one of claims 7 to 8, characterized in that: The dimensions of the I-shaped spinneret are as follows: the spinneret includes a horizontal portion and a vertical portion, the center line of the spinneret plate forms an angle with both ends, the edge of the spinneret hole has a rounded transition, and the spinneret hole forms an angle with the center line of the spinneret plate.

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