Mixed-Dtex BCF Yarn for Softness and Wear Resilience
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Solution Overview
Problem
There is a need for a yarn that balances durability with softness, as low dtex filaments are prone to breaking while high dtex filaments lack softness.
Innovation Solution
A method of forming bulked continuous filament (BCF) yarn by spinning multiple molten polymer streams through spinnerets to create filaments with varying dtex per filament, combining them, and texturizing to achieve a softer and more durable yarn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If filaments with low dtex per filament are used, then softness is improved, but durability deteriorates (prone to breaking)
Solution Approach 1:
The yarn is constructed with filaments of varying dtex values (different local qualities) where some filaments are finer (softer) and others are coarser (stronger). This creates a heterogeneous structure where different regions of the yarn cross-section have different filament properties, achieving both softness and durability simultaneously
Solution Approach 2:
The invention creates a composite filament structure within a single yarn by combining filaments of different dtex values (e.g., 1.5 dtex and 3.0 dtex) in a controlled ratio. This composite approach allows the yarn to exhibit both the softness of fine filaments and the strength of coarse filaments
2Reliability
If filaments with high dtex per filament are used, then durability is improved, but softness deteriorates
Solution Approach 1:
The yarn incorporates a mixture of fine dtex filaments (providing softness) and coarse dtex filaments (providing strength) in specific proportions. This local variation in filament quality allows the yarn to achieve both softness and durability that cannot be obtained with uniform filament construction
Solution Approach 2:
The invention changes the dtex parameter of individual filaments within the yarn by spinning different dtex values (e.g., varying from 1.5 to 3.0 dtex) while maintaining control over the distribution. This parameter variation enables optimization of both softness and durability properties
3Reliability
If multiple molten polymer streams are spun through multiple spinnerets to create varying dtex filaments, then yarn performance is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple molten polymer streams from multiple spinnerets are combined and texturized together in a single continuous process to form the final yarn. This merging approach integrates what would otherwise be separate production lines, achieving complex multi-dtex yarn structure without proportionally increasing manufacturing complexity
Solution Approach 2:
The texturizing apparatus serves multiple functions: it processes filaments from multiple spinnerets simultaneously, applies texturing to create bulk and softness, and combines filaments of different dtex values into a unified yarn structure. This multi-functionality reduces the need for separate processing equipment
Data Source
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AI summary
Various implementations include a method of forming a bulked continuous filament (BCF) yarn. The method includes providing N molten streams of polymer, providing M spinnerets, and spinning the N molten streams of polymer through the M spinnerets. At least a first group of filaments and a second group of filaments are spun through the M spinnerets. The first group of filaments each have a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different. The method further includes combining the filaments from the M spinnerets together and texturizing the spun filaments.