Composite Stretch Yarn Core Segmentation for Recovery
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Solution Overview
Problem
Existing stretch fabrics with elastic yarns in both warp and weft directions suffer from low recovery characteristics and visible surfacing of inelastic fibers through the cotton sheath, leading to reduced elasticity and fabric growth.
Innovation Solution
A composite stretch yarn with a core comprising two fibers, one being an elastomer and the other a polyester-based polymer, connected at multiple points and covered by a cotton sheath, where the second fiber provides excellent recovery properties and the core is tensioned to prevent surfacing, using intermingling or twisting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inelastic fibers are used in the core to improve recovery properties, then recovery properties are improved, but the inelastic fibers act as a block to the stretch of the elastic fiber and cause surfacing through the cotton sheath
Solution Approach 1:
The core is segmented into multiple elastic fibers (first elastic fiber and second elastic fiber) rather than mixing elastic and inelastic fibers. This segmentation allows each fiber to function independently without the inelastic fibers blocking the stretch or causing surfacing issues.
Solution Approach 2:
The invention uses a composite core structure with two different elastic fibers (elastomer and polyester-based polymer) that have complementary properties. The first elastic fiber provides high stretchability while the second elastic fiber provides excellent recovery, creating a synergistic effect without the harmful interactions of mixing elastic and inelastic fibers.
2Adaptability or versatility
If elastic yarns are used in both warp and weft directions to create bi-stretch fabrics, then stretch performance is improved, but recovery characteristics deteriorate with fabric growth of about 10%
Solution Approach 1:
The invention changes the material parameters by using a specific combination of two elastic fibers with different properties. The first elastic fiber (elastomer) provides high elongation capacity while the second elastic fiber (polyester-based polymer) provides superior recovery, achieving both high stretch performance and excellent recovery characteristics that prevent fabric growth.
Solution Approach 2:
The composite core combining two different elastic fibers creates a material with balanced stretch and recovery properties. This composite structure allows the fabric to achieve bi-stretch performance while maintaining excellent recovery characteristics, eliminating the fabric growth problem associated with traditional single-fiber elastic yarns.
3Shape
If cotton fibers sheath is used to provide natural appearance, then aesthetic properties are improved, but the core fibers may surface through the sheath after use
Solution Approach 1:
The core is segmented into multiple fine elastic fibers rather than using a single thick inelastic fiber. This segmentation allows for better distribution and coverage by the cotton sheath, preventing surfacing while maintaining the natural appearance provided by the cotton fibers.
Solution Approach 2:
The use of two different elastic fibers in the core creates a more stable and flexible core structure that better accommodates the cotton sheath. This composite core structure prevents the core fibers from pushing through the sheath during fabric use, maintaining both the natural appearance and structural integrity.
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 solution results in a fabric with improved elasticity and recovery, up to 100% higher than traditional fabrics, while maintaining a natural appearance and feel, with the core fully covered by the cotton sheath, reducing fabric growth and enhancing stretch performance.
Implementation Method 1
using intermingling or twisting techniques
Implementation Method 2
using intermingling or twisting techniques
Implementation Method 3
covered by a cotton sheath, where the second fiber provides excellent recovery properties and the core is tensioned to prevent surfacing
Implementation Method 4
the second fiber provides excellent recovery properties
Implementation Method 5
a composite stretch yarn with a core comprising two fibers, one being an elastomer and the other a polyester-based polymer
Implementation Method 6
the core is tensioned to prevent surfacing
Data Source
AI summary
In a stretch yarn (1) comprising a stretchable core (2) covered by an inelastic fibers sheath (3) the stretchable core (2) comprises first and second fibers (4, 5) that have elastic properties, the first fiber (4) is an elastomer and the second fiber (5) is a polyester based (co)polymer, the amount of the second fiber being in the range of 60-90% (w/w) of the total weight of the fibers of the stretchable core (2); the first and second fibers are connected together at least at a plurality of points (P).