Binder-Imparted Ultrafine Filament Yarn for Stable Fabric Processing
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Solution Overview
Problem
Existing ultrafine filament yarns face challenges in achieving stable processing and high-quality fabric production due to issues like alkali sensitivity, poor interweaving with weak alkali-resistant fibers, and instability in knitting processes.
Innovation Solution
A yarn comprising ultrafine filaments with a binder, specifically a sizing agent and/or oiling agent, combined with crimped composite fibers of polytrimethylene terephthalate and polyethylene terephthalate, which enhances handleability and elasticity, allowing for high-quality fabric and fiber product production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sea-island type composite fiber is used to create ultrafine filament yarn, then anti-slip performance and soft texture are improved, but processing becomes complicated and equipment restrictions increase due to alkali dissolution steps
Solution Approach 1:
The invention extracts and removes the sea component (alkali-soluble polymer) from the sea-island composite fiber through alkali treatment, leaving only the ultrafine island filaments. This extraction eliminates the need for complex equipment to handle the composite structure while maintaining the soft texture and anti-slip properties of the ultrafine filaments.
Solution Approach 2:
The binder is applied to the yarn before knitting or weaving operations. This preliminary binding action prevents yarn breakage during subsequent processing steps, eliminating the need for special equipment modifications and simplifying the overall manufacturing process while ensuring stable production.
2Shape
If alkali-soluble sea component is used in sea-island fiber, then ultrafine filament structure is achieved, but interweaving with weak alkali-resistant fibers like wool becomes difficult
Solution Approach 1:
The binder acts as an intermediary substance that coats the ultrafine filaments and provides a protective layer during interweaving operations. This intermediary layer prevents direct contact between the alkali-treated filaments and weak alkali-resistant fibers like wool, eliminating chemical incompatibility issues while maintaining the ultrafine filament structure.
Solution Approach 2:
The invention creates a composite yarn structure combining ultrafine filaments with binder materials that have compatible properties with various fibers including wool. This composite approach allows the ultrafine filament structure to be maintained while gaining versatility in interweaving with different fiber types through the binder's protective and compatibilizing effects.
3Device complexity
If ultrafine filament yarn is produced without binder, then fiber structure is simple, but yarn breakage occurs due to surface scratching by production equipment
Solution Approach 1:
The binder is applied to the yarn surface before the yarn enters production equipment during knitting or weaving operations. This beforehand cushioning creates a protective layer that absorbs mechanical stresses and prevents surface scratching by equipment components, thereby preventing yarn breakage while maintaining relatively simple yarn structure.
4Reliability
If binder is applied to ultrafine filament yarn, then knitting stability is improved, but application amount must be precisely controlled to maintain fabric quality
Solution Approach 1:
The invention optimizes the binder application parameters, specifically controlling the application amount within the range of 0.1 to 15 wt% based on yarn weight. This parameter optimization ensures sufficient binding protection for stable knitting while preventing excessive binder that would compromise fabric quality, thereby balancing knitting stability with manufacturing precision requirements.
Data Source
AI summary
The problem addressed by the present invention is to provide yarn, which includes an ultrafine filament, and that has superior handling properties, elongation and contraction properties, and with which a fabric and a fiber product of high quality can be obtained, a fabric using this yarn, and a fiber product using this yarn or fabric. The solution is imparting a binder to yarn that includes a filament A-1 with a single fiber diameter of 10 to 3000 nm and a fiber A-2 with a single fiber diameter greater than the filament A-1, and obtaining a fabric or fiber product using the yarn as necessary.