An ultra-lightweight yarn

Abstract

This invention proposes an ultralight yarn to address the problems of poor practicality, high material cost, and easy deformation of existing monofilaments. Using I-shaped PET fibers as raw material, it is prepared through specific spinneret orifices and processes. The monofilament consists of a first horizontal section, a vertical section, and a second horizontal section, with the I-shaped monofilaments interlaced and combined. Different parameters are designed for the length, width, and corner radius of each section. By controlling the angle distribution of the I-shaped spinnerets and optimizing the spinneret parameters, the fiber becomes ultralight and its performance is improved. The I-shaped design disperses stress, heat treatment optimizes performance, and the concentric spinneret orifice distribution ensures quality. This invention achieves lightweight and multifunctionality while maintaining fiber strength and elasticity, resulting in significant economic benefits and broad market prospects.

Description

Technical Field

[0001] This utility model relates to the field of polyester fiber technology, and in particular to an ultralight yarn. Background Technology

[0002] With the development of the textile industry, the performance requirements for fibers are becoming increasingly stringent. Fibers produced by traditional yarn-making methods are gradually failing to meet market demands in terms of structure and weight. A utility model patent with authorization announcement number CN111005140B discloses a "method for preparing seersucker," which uses POY technology to prepare fibers from PET, employs ring-blowing cooling, and controls the arrangement of spinnerets on the spinneret to ensure that "all spinnerets are distributed in concentric circles." Through specific crescent-shaped and I-shaped spinneret distributions, a three-dimensional crescent-shaped polyester low-elasticity yarn is obtained, enhancing the fullness and crispness of seersucker. However, the monofilament of this utility model is too heavy and feels stiff, making it inconvenient to use.

[0003] The utility model patent with authorization announcement number CN111118629B discloses a "moisture-absorbing and antibacterial knitted fabric and its preparation method". The moisture-absorbing and antibacterial knitted fabric is prepared using cotton fiber, mixed fiber and fine denier I-beam PET fiber as raw materials. The mixed fiber is extruded on the same spinneret. The PTT melt is split into two streams: one stream is directly extruded after distribution, and the other stream is distributed with the PBT melt in a parallel composite yarn manner and then extruded. The single filament crimp direction of the mixed fiber in the resulting moisture-absorbing and antibacterial knitted fabric is randomly distributed, which solves the problem of "uneven stripe". However, the material cost of this utility model is high and it is difficult to apply on a large scale.

[0004] In summary, existing yarns typically have the following drawbacks:

[0005] 1) Poor practicality: Traditional fibers use a solid round hole structure, the single filament is too heavy and feels stiff, making them inconvenient to use;

[0006] 2) High material costs: To improve fiber performance, traditional yarns use a variety of composite materials or special fibers. These materials are expensive, which increases production costs and limits their large-scale application.

[0007] 3) Easily deformed: Existing hollow yarns are easily flattened during texturing. Because the cross-sectional shape design of these yarns does not fully consider the stress during texturing, the internal structure of the fiber is prone to irreversible deformation, which in turn affects the appearance and feel of the fabric. Summary of the Invention

[0008] The purpose of this invention is to solve the problems in the prior art by proposing an ultralight yarn that can solve the problems of poor practicality, high material cost, and easy deformation.

[0009] To achieve the above objectives, this utility model proposes an ultralight yarn composed of several monofilaments with an I-shaped cross-section. The adjacent monofilaments are interwoven. The I-shape includes a first horizontal section, a vertical section, and a second horizontal section. The first horizontal section and the second horizontal section are parallel, while the vertical section and the first horizontal section are not parallel. One end of the vertical section is connected to the first horizontal section, and the other end of the vertical section is connected to the second horizontal section. The first horizontal section and the second horizontal section of the adjacent monofilaments are interwoven.

[0010] 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.

[0011] Preferably, the first horizontal line portion and the second horizontal line portion are exactly the same in size and shape, the first horizontal line portion and the vertical line portion have the same width, and the included angle at the connection between the vertical line portion and the first horizontal line portion is 80º~120º.

[0012] Preferably, the length ratio of the first horizontal line portion to the vertical line portion is 1 to 2:1, and the length ratio of the first horizontal line portion to its width is 9 to 11:1.

[0013] Preferably, the number of monofilaments in the single yarn is 50 to 288F, and the fiber fineness unit in the single yarn is 240D.

[0014] Preferably, all the monofilaments are extruded on the same spinneret along the direction parallel to the positioning groove. The spinneret holes on the spinneret are all I-shaped and arranged in concentric circles, with the I-shaped spinneret holes evenly distributed on each layer.

[0015] Preferably, the forces on the cross-sections of the I-shaped monofilaments are different, the different positions where the forces on the I-shaped monofilaments are different, and the shapes of the I-shaped monofilaments are not exactly the same.

[0016] To achieve the above objectives, this utility model also proposes a method for preparing ultralight yarn. The yarn preparation process is as follows: During the process of preparing fibers from PET using the POY process, the monofilaments are extruded on the same spinneret along the direction parallel to the positioning groove, and the arrangement of the spinneret holes on the spinneret is controlled to be concentrically distributed. All the spinneret holes are I-shaped spinneret holes. After melting and extrusion, multiple I-shaped filament bundles of the same shape are formed: polyester POY pre-oriented yarn. The filament bundles then undergo a texturing process: stretching and twisting, to obtain the yarn.

[0017] Preferably, the spinneret adopts the outer circumferential dimension printed spinneret specification, the spinneret holes are all distributed in concentric circles, the I-shaped spinneret holes are evenly distributed on each layer, the number of spinneret holes in each layer increases from the inside to the outside, and the edges of the spinneret holes are chamfered.

[0018] Preferably, the dimensions of the I-shaped spinneret are as follows: the spinneret includes a horizontal part and a vertical part, the center line of the spinneret plate is provided with an angle to both ends, the edge of the spinneret has a rounded transition, and the spinneret is provided with an angle to the center line of the spinneret plate.

[0019] The beneficial effects of this utility model are:

[0020] 1) Significantly lightweight performance: By using I-shaped monofilaments that can be stretched and twisted, the amount of material used is reduced while ensuring fiber strength and elasticity, thus reducing fiber weight and achieving an ultra-lightweight effect;

[0021] 2) Soft, breathable, and highly antibacterial: The yarn is made soft and breathable by interlacing monofilaments of 50-288F, which can wick away moisture and sweat, and feel similar to cotton, giving customers a better experience; at the same time, silver ions are added to the monofilaments for antibacterial properties, making the yarn have good antibacterial performance.

[0022] 3) Significant cost reduction: The preparation method is relatively simple and has high production efficiency, which further reduces production costs and has significant economic benefits. Under the premise of ensuring fiber quality, the production cost is effectively reduced by reducing material usage through I-shaped design and simplifying the process flow, so that high-quality fibers can be more widely used in the market and meet the price and quality needs of consumers at different levels.

[0023] 4) Wide range of applications: Ultralight I-beam fibers can be widely used in all chemical fiber textile fabrics, meeting the market demand for lightweight fibers. They are especially suitable for making lightweight, breathable, and soft-to-the-touch fabrics such as home textiles and sportswear, and have broad market application prospects.

[0024] The features and advantages of this utility model will be described in detail through embodiments and accompanying drawings. Attached Figure Description

[0025] Figure 1 This is a magnified microscope image of the cross-section of the ultralight yarn of this utility model;

[0026] Figure 2 This is a schematic diagram of the cross-sectional structure of a single filament in the ultralight yarn of this utility model;

[0027] Figure 3 This is a schematic diagram of the spinneret structure in the ultralight yarn preparation method of this utility model. Detailed Implementation

[0028] Example 1:

[0029] See Figures 1 to 3 This invention discloses an ultralight yarn composed of several monofilaments with an I-shaped cross-section. Adjacent monofilaments are interlaced. The I-shape includes a first horizontal section, a vertical section, and a second horizontal section. The first and second horizontal sections are parallel, while the vertical section is not parallel to the first horizontal section. One end of the vertical section connects to the first horizontal section, and the other end connects to the second horizontal section. The first and second horizontal sections of adjacent monofilaments are interlaced. Both ends of the first horizontal section are semicircles, which are standard circular semicircles. The center of each semicircle is located on the central axis of the first horizontal section. The diameter of the semicircle is equal to the width of the first horizontal section, and the width of the first horizontal section is equal to the radius of the semicircle. The ratio is 1 to 3:1; the first horizontal section and the second horizontal section are exactly the same in size and shape, the width of the first horizontal section and the vertical section are the same, the included angle at the connection between the vertical section and the first horizontal section is 80º to 120º, the length ratio of the first horizontal section to the vertical section is 1 to 2:1, the length-to-width ratio of the first horizontal section is 9 to 11:1, the number of monofilaments in the single yarn is 50 to 288F, the fiber fineness unit in the single yarn is 240D, the monofilaments are all extruded on the same spinneret along the 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 loops.

[0030] The yarn preparation process is as follows: During the process of preparing fibers from PET using the POY process, the monofilaments are extruded on the same spinneret along the direction parallel to the positioning groove, and the arrangement of the spinneret holes on the spinneret is controlled to be concentrically distributed. The spinneret holes are all I-shaped spinneret holes. After melting and extrusion, multiple I-shaped filament bundles of the same shape are formed: polyester POY pre-oriented yarn. The filament bundles then undergo a texturing process: stretching and twisting, to obtain the yarn. Since the monofilaments are I-shaped, they will not deform during stretching and twisting, solving the problem of hollow yarn being easily deformed during twisting.

[0031] In this embodiment, the length ratio of the first horizontal section to the vertical section is 1:1, and the lengths of the first horizontal section, the second horizontal section, and the vertical section are all 1.2 mm. The included angle at the connection between the vertical section and the first horizontal section is 90°. In the spinneret design, the spinneret holes are designed to be distributed in concentric circles, with a total of 3 concentric circles. The innermost circle has 8 H-shaped spinneret holes, and the number of spinneret holes increases by 9 in each circle outwards. The number of single filaments can reach 48-52F, and the fiber thickness unit in a single yarn is 240D. Silver ions are added to the single filaments.

[0032] In this embodiment, all parameters are within the middle of the normal range. The length ratio of the first horizontal section to the vertical section is 1:1, which allows the stress to be evenly distributed along the horizontal and vertical sections when the yarn is under tension, reducing stress concentration. The lower F number ensures a good hand feel and breathability, thereby improving the overall strength and stability of the yarn. The concentric circle layout of the spinnerets helps to improve the uniformity and stability of the spinneret process, making the extrusion of the spinnerets smoother and reducing the generation of fiber defects. Silver ions give the monofilament good antibacterial properties. This embodiment is cost-effective and suitable for all textile processing industries, such as for making lightweight fabrics and packaging materials, effectively reducing production costs while ensuring basic product quality.

[0033] Example 2:

[0034] This embodiment is basically the same as Embodiment 1, except that: the length ratio of the first horizontal line to the vertical line is 1.2:1, the length of the first horizontal line and the second horizontal line is 1.6mm, and the length of the vertical line is designed to be 1.3mm; the spinneret is designed with 4 concentric circles, the innermost circle has 6 I-shaped spinneret holes, and the number of spinneret holes increases by 8 in each circle outwards, so that the number of single filaments can reach 70 to 78F.

[0035] In this embodiment, the longer vertical yarns improve the longitudinal mechanical properties of the yarn, increase its strength, and enable it to withstand greater longitudinal tensile forces. At the same time, the increased length of the horizontal yarns also enhances the transverse connection strength. Since both the vertical and horizontal yarn lengths are taken at the upper limit, the medium F-number results in a more relaxed structure, more uniform internal stress distribution after molding, and more stable product quality. It has good application prospects in industrial hoisting and handling fields that require large longitudinal tensile forces, and can ensure good integrity and reliability when subjected to heavy tensile forces.

[0036] Example 3:

[0037] This embodiment is basically the same as Embodiment 1, except that: the length ratio of the first horizontal line to the vertical line is 2:1, the length of the first horizontal line and the second horizontal line is 1.0 mm, the length of the vertical line 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 increases by about 9 in each circle outwards. The number of single filaments can reach 138 to 144 F.

[0038] The increased number and optimized distribution of spinnerets in this embodiment help improve production efficiency and ensure yarn uniformity and stability. As the F number gradually increases, the fabric becomes more breathable and softer to the touch, without increasing the weight. The resulting yarn has a smoother surface, a denser internal structure, better wear resistance and corrosion resistance, and can adapt to harsher working environments, resulting in 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.

[0039] Working principle:

[0040] Primarily based on the unique structural design of the I-beam monofilament and its special composite method, the I-beam cross-section shape is stretchable and twistable, with good elasticity. This allows for a tighter and more uniform contact between the horizontal sections when the monofilaments interweave, effectively dispersing stress and preventing breakage due to excessive local stress. Simultaneously, the reasonable angle between the vertical and horizontal sections, along with the precise matching of dimensions in each part, further optimizes the mechanical transmission path within the yarn, enhancing its overall tensile and abrasion resistance. During the manufacturing process, controlling the shape and arrangement of the spinnerets and the heat treatment process ensures the consistency of the I-beam monofilament's quality and performance. A fiber density of 50–288F ensures breathability and a soft hand feel. The addition of silver ions provides good antibacterial properties without increasing weight, maintaining a lightweight profile. Furthermore, it only requires 240D, offering high cost-effectiveness. This allows the final ultralight yarn to fully utilize its superior performance characteristics, achieving multiple functions such as softness, breathability, moisture wicking, and significant antibacterial properties while meeting lightweight requirements.

[0041] The aforementioned I-beam structure can be used in polyester or nylon to achieve the effects of moisture absorption, perspiration wicking, and softness, and is used in high-end fabrics such as yoga wear.

[0042] The above embodiments are illustrative of the present invention and are not intended to limit the present invention. Any simple modifications to the present invention are within the protection scope of the present invention.

Claims

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

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

1.

3. The ultralight yarn as described in claim 1, characterized in that: The first horizontal line portion and the second horizontal line portion are exactly the same in size and shape. The width of the first horizontal line portion and the vertical line portion are the same. The included angle at the connection between the vertical line portion and the first horizontal line portion is 80º~120º.

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

1.

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

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

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