High Thread Count Textile Using Parallel Multi-Filament Warp Yarns
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Solution Overview
Problem
Conventional methods for producing high thread/yarn count cotton textiles are costly due to the use of compact combed cotton yarns and spun cotton in warps, limiting the speed of loom operations and increasing fabric costs.
Innovation Solution
The use of separable multi-filament parallel yarns in the warp and spun fibre yarns in the weft, with the yarns wound in groups on a beam and woven using various loom types, such as shuttle or air jet looms, to achieve a high thread/yarn count fabric with reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compact combed cotton yarns are used in the warp to achieve high thread count, then fabric quality is improved, but production cost increases
Solution Approach 1:
The patent changes the material parameter from compact combed cotton yarn to ordinary combed cotton yarn, and combines it with multi-filament polyester yarns in parallel arrangement. This parameter change maintains the high thread count (300-3000 threads per inch) while significantly reducing yarn cost, as ordinary combed cotton is more economical than compact combed variety.
Solution Approach 2:
The patent creates a composite fabric structure by combining different types of yarns (combed cotton yarn and multi-filament polyester yarn) in parallel arrangement within the warp. This composite approach allows the fabric to achieve high thread count through the combined contribution of multiple yarn types, reducing reliance on expensive single-yarn solutions.
2Manufacturing precision
If spun cotton yarn is used in the warp to achieve high thread count, then fabric quality is improved, but loom speed is reduced
Solution Approach 1:
The patent combines spun cotton yarn with multi-filament polyester yarn in parallel arrangement. The multi-filament polyester yarn contributes to the high thread count while being more suitable for high-speed loom operations, thus maintaining productivity. The composite structure allows the fabric to achieve high thread count without being entirely dependent on spun cotton yarn which limits loom speed.
Solution Approach 2:
The patent segments the warp yarn composition into multiple parallel yarns including both spun cotton and multi-filament polyester yarns. This segmentation allows different yarn types to perform different functions - cotton provides quality and polyester provides speed compatibility - thereby resolving the contradiction between thread count and loom speed.
3Manufacturing precision
If multiple parallel yarns are woven in the warp to achieve high thread count, then thread count is increased, but yarn cost increases
Solution Approach 1:
The patent changes the yarn selection parameter by choosing cost-effective ordinary combed cotton yarn instead of expensive compact combed yarn, and combines it with multi-filament polyester yarns. This parameter change allows achieving high thread count through parallel arrangement of multiple economical yarns rather than using expensive single yarn types.
Solution Approach 2:
The patent employs inexpensive ordinary combed cotton yarns and multi-filament polyester yarns in parallel arrangement to achieve high thread count. By using multiple cheaper yarns instead of fewer expensive yarns, the overall cost is reduced while maintaining the required thread count specification.
Data Source
AI summary
The present disclosure provides a high thread/yarn count textile fabric and a process of preparation thereof. The textile includes a plurality of warps and a plurality of wefts, wherein warp includes a plurality of separable multi-filament yarn. Each yarn has a denier in the range of 5 to 30. The textile fabric has a total thread/yarn count in the range of 300 to 3000 thread/yarns per inch. Each of the plurality of warps comprises 250 to 3000 ends per inch. The present disclosure uses a simple and direct process to achieve good quality textile having a high thread/yarn count at low production cost.