Composite yarn
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Solution Overview
Problem
Conventional textile manufacturing processes using PVC for sizing and setting steps are complex, affect fabric characteristics, and pose environmental hazards, necessitating improvements in yarn production and fabric finishing.
Innovation Solution
A composite yarn with a core made of thermoplastics like polyester or polyamide and a sheath of recycled PVB and TPU, which allows direct fabric setting via hot-melt, eliminating the need for additional adhesives and ensuring eco-friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PVC is used for sizing and setting steps, then fabric reinforcement is achieved, but environmental protection requirements are not met and fabric characteristics are affected
Solution Approach 1:
The patent changes the material parameter from PVC to PVB (polyvinyl butyral), which has different chemical properties but similar functional characteristics. PVB provides the necessary adhesion and reinforcement while being environmentally friendly and non-toxic, thus resolving the contradiction between environmental protection and fabric quality
Solution Approach 2:
The patent uses a composite yarn structure with core and sheath, where the sheath is made of PVB and optional additives. This composite structure allows the PVB to provide environmental benefits while the core provides structural support, maintaining fabric characteristics without relying on harmful PVC
2Ease of manufacture
If sizing and setting steps are performed after weaving, then fabric reinforcement is achieved, but process complexity increases
Solution Approach 1:
The patent incorporates the setting function directly into the yarn structure during the spinning process, rather than performing sizing and setting steps after weaving. The PVB sheath is applied preliminarily to the core yarn, enabling the fabric to be self-setting and eliminating subsequent complex processing steps while maintaining reinforcement
Solution Approach 2:
The patent merges the functions of core yarn and setting agent into a single composite yarn structure. The core provides structural support while the PVB sheath provides setting and reinforcement functions, combining multiple functions into one component and eliminating the need for separate sizing and setting processes
3Ease of operation
If thermoplastic material is used in sizing step, then fabric setting is achieved, but fabric touch and morphology are affected
Solution Approach 1:
The patent changes the material parameters of the thermoplastic from conventional PVC to PVB, which has different rheological and surface properties. PVB provides better flexibility and softer touch while maintaining the setting function, thus improving fabric touch and morphology without sacrificing setting capability
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
Simplifies textile manufacturing, maintains fabric quality, and meets environmental sustainability through the use of recycled PVB, providing smooth and comfortable fabric surfaces.
Implementation Method 1
the sheath will help the direct set of the obtained fabrics through a hot-melt step
Data Source
Figure 1
AI summary
The invention relates to a composite yarn (1). The composite yarn (1) includes a core (10) and a sheath (20). The core (10) is made of a thermoplastic material; wherein the thermoplastic material is selected from a group consisting of: a polyester, a polyamide, a polyacrylonitrile and any combination thereof. The sheath (20) formed around the core (10) is made of a cladding material, and the cladding material comprises polyvinyl butyral; wherein the polyvinyl butyral has a melt flow rate ranging from 2 g/10 min to 35 g/10 min; the melt flow rate is measured by a standard method ASTM D1238 at 190°C with 2.16 kg load.