Composite spun yarn and manufacturing method therefor

Abstract

The present invention relates to a composite spun yarn and a manufacturing method therefor and, more specifically, to a composite spun yarn and a manufacturing method therefor, wherein a composite spun yarn, in which a staple fiber for a spun yarn and an ultra-high molecular weight polyethylene (UHMWPE) staple fiber are mixed, and a manufacturing method therefor can be provided to improve properties, such as tear strength, tensile strength, seam properties, and abrasion resistance, of a fabric woven with the composite spun yarn.

Description

Composite spun yarn and its manufacturing method

[0001] The present invention relates to a composite spun yarn blended with a staple fiber for spun yarn and an ultra-high molecular weight polyethylene (UHMWPE) staple fiber, and a method for producing the same.

[0002] Generally, spun yarn refers to a thread that is formed by twisting short staple fibers such as cotton or wool and extending them in the length direction. When such spun yarn is woven into a fabric, it has the advantage of having fine hairs on the surface and excellent texture and heat retention depending on the softness, but it has the disadvantage of having poor physical properties such as tear strength, tensile strength, and abrasion resistance.

[0003] Therefore, recently, composite yarns are being developed for the purpose of complementing the above-mentioned shortcomings, as well as for reasons such as an increase in the number of industrial fields in which fibers are used and an expansion of fiber functionality according to the tastes of various consumers.

[0004] The above composite spun yarn was developed with the goal of having both the advantages of a typical natural staple fiber, such as the feel, and the functionality of a synthetic staple fiber, and to achieve this goal, rovings and filaments of various shapes and components are being applied.

[0005] As a related prior art, Korean Patent No. 10-1977060 discloses a spun yarn that uses Tencel (a type of rayon made from tree extracts, a plant fiber) or polyester (r-PES) to improve elasticity and feel.

[0006] However, these spun yarns still have not been able to solve the problems of weak tear strength, tensile strength, and wear resistance, and accordingly, there is a need to develop spun yarns that can improve their properties while maintaining the advantages of spun yarns, such as their feel.

[0007] The present invention was invented to improve the above-mentioned problems, and the object of the present invention is to provide a composite spun yarn blended with a staple fiber for spun yarn and an ultra-high molecular weight polyethylene (UHMWPE) staple fiber, and a method for manufacturing the same, thereby improving the properties of a fabric woven with the composite spun yarn, such as tear strength, tensile strength, seam resistance, and abrasion resistance.

[0008] The problems to be solved by the present invention are not limited to the problems mentioned above, and other problems to be solved by the present invention that are not mentioned herein will be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0009] The present invention provides a technical solution for a composite spun yarn characterized by being formed by blending staple fibers for spun yarn and ultra-high molecular weight polyethylene (UHMWPE) staple fibers.

[0010] In addition, the present invention provides a technical solution for a method for manufacturing a composite spun yarn, which comprises a staple fiber manufacturing step of cutting a spun fiber and an ultra-high molecular weight polyethylene fiber, respectively, to manufacture a spun fiber and an ultra-high molecular weight polyethylene staple fiber, respectively; a mixing step of mixing the spun fiber and the ultra-high molecular weight polyethylene staple fiber; a carding step of carding the mixed fiber to remove impurities and form a sliver arranged in a constant longitudinal direction; a drawing step of drawing the manufactured sliver to form a parallel arrangement; a roving step of twisting the drawn sliver while drawing it to produce a roving; a spinning step of twisting and intermingling the roving while drawing it to a predetermined thickness and spinning it; and a winding step of winding and storing the spun yarn manufactured through the spinning in a predetermined amount and shape.

[0011] When a fabric is woven using the composite spun yarn according to the present invention, there is an effect of improving the properties of the fabric, such as tear strength, tensile strength, seam strength, and abrasion resistance.

[0012] Figures 1 and 2 are process flow diagrams showing a method for manufacturing composite spun yarn according to the present invention.

[0013] The present invention provides a composite spun yarn characterized by blending staple fibers for spun yarn and ultra-high molecular weight polyethylene (UHMWPE) staple fibers, which is the best form for carrying out the invention.

[0014] More specifically, the composite spun yarn is preferably made by blending 80 to 90 wt% of Tencel staple fibers or polyester (r-PES) staple fibers, which are staple fibers used in spinning, and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers.

[0015] In addition, it is preferable that the ultra-high molecular weight polyethylene staple fiber is a Dyneema staple fiber.

[0016] Meanwhile, the ultra-high molecular weight polyethylene short fiber is surface-treated, and the surface treatment is performed by applying or impregnating 1 to 5 parts by weight of a surface modifier to 100 parts by weight of the ultra-high molecular weight polyethylene short fiber, and the surface modifier may be a mixture of vinyltriethoxysilane and vinyltri(2-methoxyethoxy)silane in a weight ratio of 1:1 to 1:2.

[0017] In addition, the present invention provides a method for producing a composite spun yarn, which comprises a staple fiber production step of cutting a spun fiber and an ultra-high molecular weight polyethylene fiber, respectively, to produce a spun fiber and an ultra-high molecular weight polyethylene staple fiber, respectively; a mixing step of mixing the spun fiber and the ultra-high molecular weight polyethylene staple fiber; a carding step of carding the mixed fiber to remove impurities and form a sliver arranged in a constant length direction; a drawing step of drawing the produced sliver to form a parallel arrangement; a roving step of twisting the drawn sliver while drawing it to produce a roving; a spinning step of twisting and intermingling the roving while drawing it to a predetermined thickness and spinning it; and a winding step of winding and storing the spun yarn produced through the spinning in a predetermined amount and shape.

[0018] Here, the above-mentioned mixing step preferably mixes 80 to 90 wt% of Tencel staple fibers or polyester staple fibers, which are staple fibers for spinning, and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers.

[0019] The advantages and features of the present invention and the method for achieving them will become clear with reference to the embodiments described in detail below together with the accompanying drawings.

[0020] However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms.

[0021] The embodiments herein are provided to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention.

[0022] And the present invention is defined only by the scope of the claims.

[0023] Accordingly, in some embodiments, well-known components, well-known operations, and well-known techniques are not specifically described to avoid obscuring the present invention.

[0024] Additionally, throughout the specification, the same reference numerals refer to the same components, and the terminology used (referred to) in this specification is for the purpose of describing embodiments and is not intended to limit the present invention.

[0025] In this specification, the singular includes the plural unless specifically stated otherwise in the phrase, and the reference to an element or action as “including (or comprising)” does not exclude the presence or addition of one or more other elements or actions.

[0026] Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used in the sense commonly understood by a person of ordinary skill in the art to which the present invention belongs.

[0027] Also, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless they are defined otherwise.

[0028] First, the composite spun yarn according to the present invention is characterized by being made by blending staple fibers for spun yarn and ultra-high molecular weight polyethylene (UHMWPE) staple fibers.

[0029] That is, by providing a composite spun yarn in which ultra-high molecular weight polyethylene short fibers are blended with short fibers for spinning, the tear strength, tensile strength, seamability, and abrasion resistance of the spun yarn are improved.

[0030] The above spinning staple fibers may be generally known as Tencel staple fibers or polyester (r-PES) staple fibers, but are not necessarily limited thereto, and various naturally occurring or synthetic staple fibers already known for spinning may be used depending on the intended use of the spinning yarn.

[0031] More specifically, the composite spun yarn is made by blending 80 to 90 wt% of Tencel staple fibers or polyester staple fibers, which are staple fibers used in spinning, and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers.

[0032] Here, if the content of the staple fiber for spinning is less than 80 wt% and the content of the ultra-high molecular weight polyethylene staple fiber exceeds 20 wt%, there is a concern that the unique touch or heat retention of the spun yarn may be reduced, and if the content of the staple fiber for spinning is more than 90 wt% and the content of the ultra-high molecular weight polyethylene staple fiber is less than 10 wt%, there is a concern that the efficiency of improving the physical properties may be reduced.

[0033] Meanwhile, the ultra-high molecular weight polyethylene short fiber is a known fiber formed of a polymer having a weight average molecular weight of 600,000 g / mol or more, and is added for the purpose of improving physical properties as described above. Dyneema short fiber (Dyneema®, DSM), which is known to have excellent physical properties, can be used.

[0034] In addition, in the case of the ultra-high molecular weight polyethylene short fiber, surface treatment can be performed to modify the surface of the short fiber to improve blendability with the short fiber for spinning.

[0035] More specifically, the surface treatment is performed by applying or impregnating 1 to 5 parts by weight of a surface modifier to 100 parts by weight of ultra-high molecular weight polyethylene single fibers, and the surface modifier is a mixture of vinyltriethoxysilane and vinyltri(2-methoxyethoxy)silane in a weight ratio of 1:1 to 1:2.

[0036] Here, if the content of the surface modifier is less than 1 part by weight, there is a concern that the mixing property improvement efficiency may be insufficient, and if it exceeds 5 parts by weight, there is a concern that some silane material may be eluted, damaging the appearance. In addition, if the composition ratio of the surface modifier is outside the above range, there is a concern that the mixing property improvement efficiency may be insufficient.

[0037] Hereinafter, the present invention will be described in detail by way of examples, but the present invention is not necessarily limited to the following examples.

[0038] 1. Manufacturing of composite yarns and fabrics

[0039] (Example 1)

[0040] 90 wt% of polyester staple fibers for spinning and 10 wt% of ultra-high molecular weight polyethylene staple fibers (Dyneema®, DSM) were mixed and spun to produce spun yarn, and then the spun yarns were used as warp and weft yarns to weave a fabric.

[0041] (Example 2)

[0042] 80 wt% of Tencel staple fibers, which are staple fibers for spinning, and 20 wt% of ultra-high molecular weight polyethylene staple fibers (Dyneema®, DSM) were mixed and spun to produce spun yarn, and then the spun yarns were used as warp and weft yarns to weave a fabric.

[0043] (Comparative Example 1)

[0044] After spinning 100% by weight of polyester staple fibers, which are staple fibers for spinning, to produce spun yarn, the spun yarns were used as warp and weft yarns to weave fabric.

[0045] (Comparative Example 2)

[0046] After spinning 100% by weight of Tencel staple fibers, which are staple fibers for spinning, to produce spun yarn, the spun yarns were used as warp and weft yarns to weave fabric.

[0047] The compositions according to the above examples and comparative examples are summarized in [Table 1] below.

[0048] (Unit: weight%) Classification Example 1 Example 2 Comparative Example 1 Comparative Example 2 Polyester staple fiber 90-100 - Tencel staple fiber - 80-100 Ultra-high molecular weight polyethylene staple fiber 1020 -

[0049] 2. Evaluation of composite spun yarn fabrics

[0050] The weight, tear strength, tensile strength, hardness, and wear resistance of the above examples and comparative examples were evaluated, and the test criteria and results are as follows [Table 2].

[0051] Classification Test Standard Unit Example 1 Example 2 Comparative Example 1 Comparative Example 2 Weight SOP 4g / sqm 228 227 215 213 Tear Strength ASTM D2262 NA:146 / B:249 A:144 / B:245 A:52 / B:79 A:50 / B:77 Tensile Strength ASTM 5035 N / cm A:491 / B:286 A:490 / B:284 A:171 / B:105 A:169 / B:104 Seam Strength ASTM D638 N / cm A:176 / B:96 A:174 / B:95 A:92 / B:66 A:91 / B:63 Abrasion Resistance ISO 12947-2(CP918A P400, 9kPa)Cycles40 cycles without PU coating300 cycles with PU coating500 cycles with EAR coating40 cycles without PU coating300 cycles with PU coating500 cycles with EAR coating20 cycles without PU coating100 cycles with PU coating200 cycles with EAR coating coating20 cycles without PU coating100 cycles with PU200 cycles with EAR coating

[0052] As shown in the above [Table 2], it can be seen that the fabric woven with the composite spun yarn according to the embodiment of the present invention has much better physical properties than the fabric woven with the conventional spun yarn. Next, a method for manufacturing a composite spun yarn according to the present invention will be described with reference to the attached drawings. FIGS. 1 and 2 are process flow diagrams showing a method for manufacturing a composite spun yarn according to the present invention. As shown in FIGS. 1 and 2, the present invention includes a single fiber manufacturing step (S100), a kneading step (S200), a carding step (S300), a drawing step (S400), a roving step (S500), a spinning step (S600), and a winding step (S700).

[0053] The above-mentioned short fiber manufacturing step (S100) is a step of manufacturing short fibers for spinning and ultra-high molecular weight polyethylene fibers by cutting the fibers for spinning and ultra-high molecular weight polyethylene fibers, respectively. Short fibers can be manufactured with an average fiber length of 10 to 60 mm using a fiber cutting machine (e.g., rotary cutter, guillotine cutter, etc.), but are not limited thereto, and various lengths can be applied according to the intended use of the spinning yarn.

[0054] The above mixing step (S200) is a step of mixing the spinning staple fibers and ultra-high molecular weight polyethylene staple fibers. Using general mixing equipment (such as a rapid changer, a dust collector, or a mixer), 80 to 90 wt% of spinning staple fibers such as Tencel staple fibers or polyester staple fibers and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers can be mixed. Since the description of this composition has already been described above, it is omitted here.

[0055] Meanwhile, in the above-mentioned mixing step (S200), in addition to the mixing process, an opening process for separating large fiber bundles into small fiber bundles (tufts), a cleaning process for removing mixed impurities such as foreign matter and nep yarn, and a lap formation process for creating a lap with a uniform thickness and width may be additionally performed.

[0056] The above carding step (S300) is a step of carding the mixed fibers to remove impurities and form slivers arranged in a certain length direction. In order for the drawing process to be described later to be performed more smoothly, the fibers are fed into a general carding machine and combed to remove impurities and form slivers arranged in a certain length direction.

[0057] Meanwhile, for higher strength and uniformity, slivers that have gone through the carding stage (S300) can be combed using a combing machine.

[0058] The above-mentioned drawing step (S400) is a step for drawing the manufactured sliver to form a parallel arrangement. Even after the carding step (S300), uneven or non-directional arrangements remain within the sliver, so usually 5 to 15 sliver strands are fed into a drawing frame and the draft ratio is adjusted to improve the uniformity.

[0059] Meanwhile, in the present invention, it is exemplified that the spinning staple fibers and ultra-high molecular weight polyethylene staple fibers are mixed and then subjected to a drawing step (S400), but in addition, the spinning staple fibers and ultra-high molecular weight polyethylene staple fibers may be separately kneaded and carded and then mixed in the drawing step (S400).

[0060] The above-mentioned roving step (S500) is a step for manufacturing roving by twisting the above-mentioned softened sliver while drawing it. Since there is a concern that the sliver itself may not be able to properly produce spun yarn, the sliver is drawn in the roving step (S500) to lower the linear density and twisted so that yarn of the desired thickness can be spun in the spinning step (S600) described later.

[0061] The above-mentioned spinning step (S600) is a step of spinning the above-mentioned yarn by twisting and intermingling it while stretching it to a predetermined thickness. Through the above-mentioned twisting and three-dimensional intermingling, the focusing force between fibers is increased. It is common to spin the yarn with a count of 1 to 100, but this is not limited to this, and various counts can be applied depending on the intended use of the yarn.

[0062] Meanwhile, the above-mentioned specified thickness refers to the thickness desired by the producer and is not limited to a specific thickness.

[0063] The above-mentioned winding step (S700) is a step of winding and storing the spun yarn manufactured through the spinning process in a predetermined amount and shape. In this step, general processes such as winding, twisting, and singeing can be additionally performed.

[0064] Meanwhile, the above-mentioned specified quantity and shape also refer to the quantity and shape desired by the producer and are not limited to a specific quantity or thickness.

[0065] That is, the present invention provides a composite spun yarn mixed with a single fiber for spinning and an ultra-high molecular weight polyethylene single fiber, and a method for manufacturing the same, thereby improving the properties of a fabric woven with the composite spun yarn, such as tear strength, tensile strength, core strength, and abrasion resistance.

[0066] As described above, the present invention is based on the fundamental technical concept of providing a composite spun yarn and a method for manufacturing the same. Furthermore, it is clear that numerous other modifications and applications are possible within the scope of the fundamental technical concept of the present invention, and are readily apparent to those skilled in the art.

[0067] When a fabric is woven using the composite spun yarn according to the present invention, it is expected to be widely used in industry because it has the effect of improving the properties of the fabric, such as tear strength, tensile strength, seam strength, and abrasion resistance.

Claims

1. A composite spun yarn characterized by being made by blending staple fibers for spun yarn and ultra-high molecular weight polyethylene (UHMWPE) staple fibers.

2. In the second paragraph, The above composite spun yarn is, A composite spun yarn characterized by being made by blending 80 to 90 wt% of Tencel staple fibers or polyester (r-PES) staple fibers, which are staple fibers for spinning, and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers.

3. In paragraph 2, A composite spun yarn characterized in that the above ultra-high molecular weight polyethylene staple fiber is a Dyneema staple fiber.

4. In paragraph 2, The above ultra-high molecular weight polyethylene single fiber is surface treated, The above surface treatment is performed by applying or impregnating 1 to 5 parts by weight of a surface modifier to 100 parts by weight of ultra-high molecular weight polyethylene single fiber. A composite spun yarn characterized in that the surface modifier is a mixture of vinyltriethoxysilane and vinyltri(2-methoxyethoxy)silane in a weight ratio of 1:1 to 1:

2.

5. A short fiber manufacturing step of cutting the fiber for spinning and the ultra-high molecular weight polyethylene fiber, respectively, to manufacture the short fiber for spinning and the ultra-high molecular weight polyethylene short fiber, respectively; A mixing step of mixing the above spinning staple fibers and ultra-high molecular weight polyethylene staple fibers; A carding step of removing impurities from the above mixed fibers and forming slivers arranged in a certain length direction; A drawing step for drawing the above-mentioned manufactured sliver to form a parallel arrangement; A roving step of manufacturing a roving by twisting and stretching the above-mentioned softened sliver; A spinning step in which the above investigation is stretched to a predetermined thickness and then twisted and intermingled to spin the yarn; and A method for producing a composite spun yarn, characterized by including a winding step of winding and storing the spun yarn produced through the above spinning in a predetermined amount and shape.

6. In paragraph 5, The above mentioned stage of confusion is, A method for producing a composite spun yarn, characterized by mixing 80 to 90 wt% of Tencel staple fibers or polyester staple fibers, which are staple fibers for spinning, and 10 to 20 wt% of ultra-high molecular weight polyethylene staple fibers.

Images