Core-spun yarn process steps and system

Abstract

The present application provides a core-spun yarn manufacturing process and system, comprising the following steps: (a) dyeing the core yarn to form a color layer; (b) drying in a vacuum environment to improve dye adhesion; (c) heating the outer covering material to a molten state and injecting it into a mold; (d) evenly covering the molten material on the core yarn while maintaining the tension of the core yarn to form an outer covering layer; (e) cooling to solidify the outer covering layer; (f) winding the finished core-spun yarn; the system sequentially comprises a core yarn shaft support, a dyeing device, a vacuum drying device, an injection molding device, a cooling unit, and a yarn winding shaft support along the conveying path; thereby improving the adhesion of the dye, reducing the color loss and color difference problems during use, and improving the color performance and texture of the core-spun yarn product.

Description

Technical Field

[0001] This invention relates to the field of core-spun yarn production, and more particularly to a core-spun yarn manufacturing process and system. Background Technology

[0002] With advancements in technology and diversification of market demands, the performance requirements for fabrics are increasingly stringent. Traditional fabric manufacturing processes typically rely on blending different types of yarns to achieve desired properties. However, this method presents several problems: 1. Performance Imbalance: When manufacturers increase the proportion of a yarn to enhance a specific property, the proportion of other yarns inevitably decreases, preventing their properties from being fully realized in the final fabric. 2. Manufacturing Complexity: The blending ratio of different yarns requires precise control, increasing the complexity and cost of the production process. 3. Performance Limitations: Traditional methods cannot fully utilize the advantages of various yarns, limiting the diversity of fabric properties.

[0003] To address these issues, a core-spun yarn has emerged on the market. This core-spun yarn consists of a core yarn and an outer covering layer, with the outer covering layer uniformly coating the surface of the core yarn. Its manufacturing method includes the following steps: (a) heating the outer covering material to a molten state; (b) passing the core yarn through the molten outer covering material while maintaining a certain tension, allowing the outer covering material to uniformly adhere to the surface of the core yarn; and (c) after the outer covering material cools, a stable covering layer is formed, completing the manufacturing of the core-spun yarn.

[0004] The color of the core-spun yarn can be obtained in two ways: one is by adding color masterbatch to the outer covering material to give the outer covering layer its color; the other is that the core yarn itself has a color, while the outer covering layer is transparent. In this case, the color of the core yarn can be the natural color of the material or it can be dyed. However, if the color of the core yarn is obtained by dyeing, and the outer covering layer is applied directly after dyeing, the color adhesion will be insufficient, which can easily lead to problems such as color fading, color difference, and poor consistency in the finished product. This will affect the color presentation of the final product and reduce the overall quality. Summary of the Invention

[0005] This invention provides a core-spun yarn manufacturing process and system. The core-spun yarn manufacturing process includes: (a) a dyeing step, selecting the desired color and dyeing the core yarn to form a color layer on the surface of the core yarn; (b) a vacuum drying step, placing the dyed core yarn into a vacuum drying device and drying it in a vacuum environment; (c) a heating and melting step, heating the outer covering material to a molten state and then injecting it into a mold; (d) a core yarn covering step, while maintaining a certain tension on the core yarn, uniformly attaching the molten outer covering material onto the core yarn through the mold to form an outer covering layer on the surface of the color layer; (e) a cooling step, cooling the covered core yarn to solidify the outer covering layer, thereby forming a complete core-spun yarn; and (f) a yarn winding step, winding the completed core-spun yarn onto a yarn bobbin to complete the core-spun yarn manufacturing process. Its core-spun yarn manufacturing system is used to produce core-spun yarn along a conveying path. The system, along the conveying path, sequentially includes: a core yarn bobbin, located at the beginning of the conveying path, for holding the pre-made core yarn; a dyeing device for dyeing the core yarn to form a color layer on its surface; a vacuum drying device for drying the color layer under vacuum; and an injection molding device including a barrel, a feed tube, a screw, and a mold. The barrel is used to hold the outer covering material, and the feed tube is connected to the barrel and has an internal structure... A pipe has an injection port at one end. A screw passes through the pipe and is responsible for pushing and heating the outer covering material to a molten state. A mold is connected to the injection port, allowing the core yarn to pass through and combine with the molten outer covering material. An outer covering layer is uniformly attached to the color layer surface of the core yarn to form a core-spun yarn. A cooling unit has at least one cooling tank filled with coolant for cooling the core-spun yarn as it passes through. A take-up beam is located at the end of the conveying path for taking up the core-spun yarn.

[0006] The main purpose of the core-spun yarn manufacturing process and system of the present invention is that, after the core yarn is dyed, it is dried in a vacuum state by a vacuum drying device, which significantly improves the adhesion and effect of dyeing. This can effectively reduce problems such as color fading, color difference and poor consistency of core-spun yarn during use, thereby improving the color performance and overall texture of the product. Attached Figure Description

[0007] Figure 1 This is a block flowchart of the present invention.

[0008] Figure 2 This is a schematic diagram of the architecture of the present invention.

[0009] Figure 3 This is a schematic diagram of the staining steps of the present invention.

[0010] Figure 4This is a schematic diagram of the vacuum drying step of the present invention.

[0011] Figure 5 This is a schematic diagram of the heating and melting step and the core yarn coating step of the present invention.

[0012] Figure 6 This is a schematic diagram of the cooling steps of the present invention.

[0013] Figure 7 This is a schematic diagram of the yarn taking-up step of the present invention.

[0014] Figure 8 This is a perspective view of the core-spun yarn of the present invention.

[0015] Figure Labels

[0016] S101 Staining Procedure

[0017] S102 Vacuum Drying Step

[0018] S103 Heating and Melting Steps

[0019] S104 Covered Core Yarn Steps

[0020] S105 Cooling Steps

[0021] S106 Yarn gathering steps

[0022] 1A core yarn

[0023] 1B color layer

[0024] 1C outer coating

[0025] 1 core-spun yarn

[0026] 10-core yarn beam frame

[0027] 20 dyeing equipment

[0028] 30 Vacuum Drying Unit

[0029] 31 enclosures

[0030] 32 rooms

[0031] 33 heating units

[0032] 34. Air extraction equipment

[0033] 40 Injection Molding Unit

[0034] 41 barrel

[0035] 42 material pipe

[0036] 421 pipe

[0037] 422 injection port

[0038] 43 screw

[0039] 44 mold

[0040] 50 cooling units

[0041] 51 Cooling Tank

[0042] 60 yarn take-up beams Detailed Implementation

[0043] The following description, in conjunction with the drawings of preferred embodiments of the present invention, is intended to enable those skilled in the art to implement the invention based on the statements in this specification.

[0044] First, please refer to the following: Figures 1 to 8 As shown, the core-spun yarn manufacturing process of the present invention includes the following steps:

[0045] (a) Dyeing step S101: Using digital printing, inkjet dyeing, UV dyeing, immersion dyeing, etc., select the desired color to dye the core yarn 1A and form a color layer 1B on the surface of the core yarn 1A. The core yarn 1A can be made of suitable fiber material, such as polyester fiber or nylon, and can be monofilament or multifilament yarn.

[0046] (b) Vacuum drying step S102: The dyed core yarn 1A is sent into a vacuum drying device 20 and dried in a vacuum environment to avoid gas encapsulation, improve the adhesion of the color layer 1B, and remove excess moisture to improve the subsequent coating effect.

[0047] (c) Heating and melting step S103: The transparent outer covering material is heated to a molten state and then injected into a mold 44 to prepare for the covering. The outer covering material is a thermoplastic.

[0048] (d) In the core yarn coating step S104, while maintaining a certain tension on the core yarn 1A, the molten outer coating material is uniformly attached to the core yarn 1A through the mold 44, and a transparent outer coating layer 1C is formed on the surface of the color layer 1B of the core yarn 1A.

[0049] (e) Cooling step S105: Cool the core yarn 1A that has been covered to solidify the outer covering layer 1C, thereby forming a complete core-spun yarn 1.

[0050] (f) Yarn winding step S106: The completed core-spun yarn 1 roll is wound onto the yarn bobbin and the production process of core-spun yarn 1 is completed.

[0051] The present invention provides a core-spun yarn manufacturing system for producing core-spun yarn along a conveying path. The core-spun yarn manufacturing system includes, in sequence along the conveying path: a core yarn bobbin 10, a dyeing device 20, a vacuum drying device 30, an injection molding device 40, a cooling unit 50, and a take-up bobbin 60.

[0052] The core yarn holder 10 is located at the beginning of the conveying path and is used to place the pre-made core yarn 1A.

[0053] The dyeing equipment 20 is used to dye the core yarn 1A to form a uniform color layer 1B on the surface of the core yarn 1A to achieve the desired color effect. The dyeing equipment 20 can be a digital printing and dyeing machine, an inkjet dyeing machine, a UV printing machine, or an immersion dyeing machine.

[0054] The vacuum drying device 30 dries the color layer 1B under vacuum conditions, accelerating the curing process of the color layer 1B. The vacuum drying device 30 includes a box 31, inside which is a chamber 32. The chamber 32 is equipped with a heating unit 33. An air extraction device 34 is provided outside the box 31 to extract the air from the chamber 32 and form a vacuum environment.

[0055] The injection molding apparatus 40 includes a barrel 41, a tube 42, a screw 43, and a mold 44. The barrel 41 is used to hold the outer covering material. The tube 42 is connected to the barrel 41 and has a pipe 421 inside, with an injection outlet 422 at one end. The screw 43 passes through the pipe 421 of the tube 42 and is responsible for pushing and heating the outer covering material to a molten state. The mold 44 is connected to the injection outlet 422. The molten outer covering material is injected into the mold 44 through the injection outlet 422. The mold 44 allows the core yarn 1A to pass through and combine with the molten outer covering material. An outer covering layer 1C is uniformly attached to the surface of the color layer 1B of the core yarn 1A to form a core-spun yarn 1.

[0056] The cooling unit 50 is provided with at least one cooling tank 51, which is filled with coolant for the newly formed core-spun yarn 1 to pass through for cooling treatment and quickly solidify the outer covering layer 1C.

[0057] The take-up beam 60 is located at the end of the conveying path and is used to take up the core-spun yarn 1 for convenient subsequent storage and transportation.

[0058] The following beneficial effects can be obtained from the above specific embodiments:

[0059] The present invention relates to a core-spun yarn manufacturing process and system, wherein the core yarn 1A is dried in a vacuum state by a vacuum drying device 30 after dyeing treatment, which significantly improves the adhesion of dyeing and the subsequent coating effect. This can effectively reduce problems such as color fading, color difference and poor consistency of core-spun yarn 1 during use, thereby improving the color performance and overall texture of the product and meeting the market demand for high-quality core-spun yarn 1.

[0060] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the present invention. The scope of protection of the present invention is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within its spirit and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of the present invention.

Claims

1. A core-spun yarn manufacturing process, comprising: (a) Dyeing step: Select the desired color and dye the core yarn to form a color layer on the surface of the core yarn; (b) Vacuum drying step: The dyed core yarn is placed in a vacuum drying device and dried in a vacuum environment; (c) Heating and melting step: heating the outer coating material to a molten state and then injecting it into a mold; (d) The core yarn coating step involves uniformly attaching the molten outer coating material onto the core yarn through the mold while maintaining a certain tension on the core yarn, thereby forming an outer coating layer on the surface of the color layer. (e) Cooling step: Cool the covered core yarn to solidify the outer covering layer, thereby forming a complete core-spun yarn; (f) Yarn winding step: The completed core-spun yarn roll is wound onto the yarn bobbin and the core-spun yarn production process is completed.

2. The core-spun yarn manufacturing process according to claim 1, wherein the core yarn can be a monofilament or a multifilament yarn.

3. The core-spun yarn manufacturing process according to claim 1, wherein the outer covering material is a thermoplastic.

4. The core-spun yarn manufacturing process according to claim 1, wherein the outer covering layer is transparent.

5. A core-spun yarn manufacturing system for producing core-spun yarn along a conveying path, the core-spun yarn manufacturing system comprising, sequentially along the conveying path: A core yarn bobbin holder is set at the beginning of the conveying path to hold the pre-made core yarn; A dyeing device is used to dye the core yarn to form a color layer on the surface of the core yarn; A vacuum drying device is used to dry the color layer under vacuum conditions; An injection molding apparatus includes a barrel, a tube, a screw, and a mold. The barrel is used to hold the outer covering material. The tube is connected to the barrel and has a pipe inside, with an injection outlet at one end. The screw passes through the pipe and is responsible for pushing and heating the outer covering material to a molten state. The mold is connected to the injection outlet, allowing the core yarn to pass through and combine with the molten outer covering material. An outer covering layer is uniformly attached to the color layer surface of the core yarn to form a core-spun yarn. A cooling unit is provided with at least one cooling tank containing coolant for cooling the core-spun yarn as it passes through; and A take-up beam is located at the end of the conveying path and is used to take up the core-spun yarn.

6. The core-spun yarn manufacturing system according to claim 5, wherein the dyeing equipment is a digital dyeing machine, an inkjet dyeing machine, a UV printing machine, or an immersion dyeing machine.

7. The core-spun yarn manufacturing system according to claim 5, wherein the vacuum drying device includes a box, the inside of which is provided a chamber, the chamber is provided with a heating unit, and an air extraction device is provided outside the box for extracting air from the chamber to form a vacuum environment.

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