Crosslinked Chitosan Yarn Sizing for Thin Yarn Weavability
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Solution Overview
Problem
Thin yarns made from natural animal fibers, vegetable fibers, or synthetic fibers face challenges in weaving due to breakage, low density in fabric design, high water and energy consumption, color fastness issues, and dimensional stability problems in existing processes, which require improvement for mechanical properties, environmental sustainability, and finishing processes.
Innovation Solution
A process using crosslinked chitosan as a sizing agent, applied through UV radiation and partially removed during finishing, enhances yarn cohesion, mechanical resistance, and affinity for dyeing and printing, while maintaining softness and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-soluble PVA reinforcement yarn is used to improve weavability of thin yarn, then yarn breakage is reduced, but high setts (high density coefficients) cannot be provided because the yarn occupies twice the final yarn space before dissolution
Solution Approach 1:
The patent extracts and removes the water-soluble PVA reinforcement yarn after weaving by immersing the fabric in slightly acid water solution at 85-95°C, allowing the fabric to achieve high density while maintaining yarn integrity during the weaving process
Solution Approach 2:
The PVA reinforcement yarn is incorporated into the yarn structure before weaving to provide necessary strength, then removed after weaving to achieve the desired high fabric density, thus performing the reinforcement function in advance when needed
2Reliability
If water-soluble PVA reinforcement yarn is used to improve weavability, then thin yarn can be woven without breaking, but high consumption of PVA is required which is entirely disposed of in wastewater
Solution Approach 1:
The PVA reinforcement yarn is discarded after serving its purpose during weaving by dissolving it in acid water solution, removing it from the final fabric product while acknowledging its temporary functional role in the manufacturing process
3Reliability
If high temperature (85-95°C) is used to dissolve PVA reinforcement yarn, then complete dissolution is achieved, but color fastness problems occur due to long-time exposure to high temperatures
Solution Approach 1:
The patent uses slightly acid water solution (pH adjustment) as a alternative parameter change to enable PVA dissolution at lower temperatures, thereby avoiding the color fastness problems associated with prolonged high temperature exposure while still achieving complete reinforcement yarn removal
4Reliability
If high temperature (85-95°C) is used to dissolve PVA reinforcement yarn, then complete dissolution is achieved, but felting occurs which involves dimensional stability problems
Solution Approach 1:
The patent employs acid water solution (pH modification) as a parameter change to dissolve PVA at reduced temperatures, preventing felting and maintaining fabric dimensional stability while still achieving complete removal of the reinforcement yarn
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process improves the mechanical properties and weavability of thin yarns, enabling high-density knit designs, reduces environmental footprint, and enhances dyeing and printing performance with improved antibacterial and antifelting effects.
Implementation Method 1
crosslinking the chitosan of said reinforcement product applied to the fibers of said yarn by UV radiation
Implementation Method 2
a desizing step, providing partial and calibrated removal of said crosslinked chitosan-derived reinforcement product anchored to the fibers of said yarn, from such fibers of said yarn
Data Source
AI summary
A process for improving weavability of a yarn comprises a step of application of a chitosan-containing reinforcement product and a later chitosan crosslinking step.