Core-Sheath Yarn With Textured Polymer Fibers for Cotton Reduction
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Solution Overview
Problem
Existing composite yarns with elastic cores require a high amount of cotton to prevent core surfacing, leading to high costs, environmental impact, and unsatisfactory fabric appearance due to curling and high water and energy consumption.
Innovation Solution
A composite yarn design with a core comprising at least 35% polymeric non-elastomeric fibers, covered by a reduced amount of sheath fibers, preferably cotton, using a spinning process like ring or siro spinning to minimize core surfacing and enhance elasticity and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high amount of cotton sheath fibers is used to prevent core surfacing, then the core is completely covered and appearance is improved, but the cost increases and environmental impact worsens
Solution Approach 1:
The invention changes the physical and chemical parameters of the core fibers, specifically using textured polymeric filaments with controlled linear density (1.6-6.7 dtex per filament) and texturing degree (3-8 times original length). These parameter changes increase the core's bulk and coverage efficiency, allowing complete core coverage with reduced cotton sheath content (20-40% of total yarn weight) while maintaining appearance quality and preventing core surfacing.
Solution Approach 2:
The invention creates a composite yarn structure combining textured polymeric core fibers with cotton sheath fibers in optimized proportions. The composite design uses the textured core to provide bulk and coverage while the reduced cotton sheath provides aesthetic appearance, achieving both complete core coverage and visual quality with lower overall cotton content compared to conventional yarns.
2Reliability
If long cotton fibers are used to provide good appearance, then fabric appearance is improved, but the cost increases
Solution Approach 1:
The invention changes the fiber structure by using textured polymeric filaments with controlled linear density and texturing ratios. This creates a core structure that maintains yarn uniformity and prevents curling without requiring expensive long cotton fibers, achieving good fabric appearance with more cost-effective fiber combinations.
Solution Approach 2:
The invention applies different fiber types and structures to different parts of the yarn: the core uses textured polymeric filaments for structural integrity and coverage, while the sheath uses cotton fibers for aesthetic appearance. This local differentiation allows optimization of each region's function, achieving good appearance with reduced overall cost.
3Reliability
If highly twisted short fibers are used to prevent core surfacing, then core coverage is improved, but the yarn becomes curly and appearance deteriorates
Solution Approach 1:
The invention changes the twist parameters to a moderate range (1.5-3.5 twists per cm) rather than high twist, and combines this with textured core fibers that have inherent bulk and volume. This parameter combination provides sufficient core coverage while maintaining yarn uniformity and preventing excessive curling, avoiding the appearance deterioration caused by highly twisted short fibers.
Solution Approach 2:
The invention segments the yarn into distinct core and sheath regions with different fiber characteristics. The textured core filaments are segmented into multiple fine denier components (1.6-6.7 dtex each) that collectively provide coverage without requiring high twist, while the sheath fibers provide a smoothing effect that maintains overall yarn uniformity.
4Reliability
If a high amount of cotton is used to cover the core, then core surfacing is prevented, but water and energy consumption increases
Solution Approach 1:
The invention changes the cotton content parameter to an optimized range (20-40% of total yarn weight) rather than using high amounts of cotton. The textured core structure provides enhanced coverage efficiency, allowing complete core protection with reduced cotton content, thereby decreasing water and energy consumption associated with cotton cultivation, harvesting, and processing.
Data Source
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AI summary
A composite yarn (1) having a core (2) and a sheath (3), preferably comprising staple fibers (3a), said core (2) comprising at least one polymeric core fiber (21), preferably a plurality of core fibers (21), made of polymeric material, wherein the total amount of the core fibers (21) is at least 35% by weight of the total weight of the composite yarn (1), and wherein the core fiber (21) and the sheath (3) are spun together.