Composite Yarn Structure for Evenness and Staple Fiber Retention

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Solution Overview

Problem

Existing filament-staple fiber composite yarn production methods face limitations due to fiber loss and inconsistency, particularly with recycled fibers, affecting mechanical properties and usability, and are restricted by traditional manufacturing techniques.

Innovation Solution

A novel binding form of staple fibers within filaments, where staple fibers are firmly bound inside filaments, preventing loss and ensuring excellent evenness and processability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional ring spinning techniques are used to manufacture composite yarns with recycled fibers, then production can proceed with traditional methods, but staple fibers are lost and fiber efficiency is reduced

Engineering Contradiction:

Improvemanufacturing methodVSAvoidstaple fiber loss

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent applies nesting by inserting staple fibers inside the filament structure, where staple fibers are placed within the hollow core or between filament layers of the composite yarn. This nested configuration prevents staple fiber loss during processing while maintaining the integrity of the filament outer layer, directly resolving the contradiction between ease of manufacture and staple fiber retention.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If Sirospun method is used to produce composite yarns, then a wide range of fiber mixtures can be accommodated, but fiber efficiency is lower due to physical clumping and inconsistencies

Engineering Contradiction:

Improvefiber mixture compatibilityVSAvoidyarn evenness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies segmentation by dividing the composite yarn into distinct functional zones: an outer filament layer that provides structural integrity and an inner core region that accommodates staple fibers. This segmented structure prevents physical clumping of staple fibers while maintaining consistent yarn properties, resolving the contradiction between fiber mixture versatility and manufacturing precision.

Inventive Principle:

Principle #1Segmentation

3Productivity

If sirofil method is used to manufacture composite yarns, then production efficiency is improved, but application to different fiber mixtures is limited

Engineering Contradiction:

Improveproduction efficiencyVSAvoidfiber mixture variety

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent applies universality by designing a composite yarn structure where the filament-staple fiber configuration can accommodate various fiber types and ratios. The standardized nested structure allows different fiber mixtures to be processed through the same manufacturing approach, enabling both high productivity and broad adaptability to different fiber combinations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If staple fibers are loosely arranged in composite yarns, then manufacturing is simpler, but mechanical properties and integrity are compromised

Engineering Contradiction:

Improveyarn formationVSAvoidyarn mechanical properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies nesting by positioning staple fibers within the protected inner region of the filament structure, where they are held in place by the surrounding filament layers. This nested arrangement provides both simple manufacturing (staple fibers are easily inserted) and strong mechanical properties (staple fibers are securely retained), resolving the contradiction between ease of manufacture and yarn strength.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 composite yarn exhibits excellent tensile strength, elongation, and appearance without staple fiber loss, enabling wide application in fabrics and articles such as automobile interiors and shoe parts.

Implementation Method 1

a filament portion including a plurality of filaments twisted on an outer surface of the staple fiber portion

Methodology Applied

Scientific EffectTwisting:

Data Source

PatentEP4682299A1Fabric comprising filament-staple fiber composite yarn with excellent evenness

Publication Date: 2026.01.21 HYUNDAI MOTOR CO LTD

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AI summary

The present disclosure relates to a fabric comprising a filament-staple fiber composite yarn. The filament-staple fiber composite yarn comprises filaments and staple fibers, wherein the staple fibers are inserted into the filaments, so that the filament-staple fiber composite yarn exhibits excellent evenness and a fabric manufactured therefrom has excellent processability and appearance.