Multi-Component Yarn Abrasion Resistance and Pilling
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Solution Overview
Problem
Existing legwear such as socks and stockings face challenges in combining high abrasion resistance with low pilling tendency, as current multi-component yarns either improve abrasion resistance at the cost of increased pilling or vice versa, and often lack moisture absorption and comfort due to deficiencies in air permeability and moisture management.
Innovation Solution
A multi-component yarn composed of an air-blown textured polyamide filament yarn and a spun-twisted staple fiber yarn, with the staple fiber yarn comprising a mixture of natural and synthetic fibers, including viscose, which are twisted together to create a yarn with high abrasion resistance and low pilling tendency, while maintaining the soft feel and moisture absorption of viscose fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cotton yarn or viscose fibers are used to improve moisture absorption and soft feel, then wearing comfort is improved, but abrasion resistance deteriorates significantly
Solution Approach 1:
The patent applies composite materials by combining polyamide filament yarn (providing abrasion resistance) with cotton or viscose staple fiber yarn (providing moisture absorption and soft feel) into a multi-component yarn. This composite structure allows the fabric to simultaneously achieve high abrasion resistance and good wearing comfort, resolving the contradiction between durability and comfort.
2Strength
If polyamide or polyester fibers are used to improve abrasion resistance, then durability is improved, but pilling tendency increases
Solution Approach 1:
The patent combines synthetic filament yarn (polyamide or polyester) with natural or semi-synthetic staple fiber yarn (cotton or viscose) in a multi-component yarn structure. The synthetic component provides abrasion resistance while the staple fiber component reduces pilling tendency, achieving both durability and low pilling through material composition.
Solution Approach 2:
The patent applies local quality by creating a yarn structure where different components have different functions: the filament yarn provides structural integrity and abrasion resistance, while the staple fiber yarn provides surface quality and reduces pilling. This localized functional distribution resolves the contradiction between durability and surface quality.
3Strength
If multi-component yarns with synthetic filament and staple fiber are used to improve abrasion resistance, then durability is improved, but moisture absorption and air permeability deteriorate
Solution Approach 1:
The patent uses composite materials combining synthetic filament yarn (for abrasion resistance) with natural or semi-synthetic staple fiber yarn (cotton or viscose, for moisture absorption). The staple fiber component maintains high moisture absorption capacity and air permeability while the filament component provides durability, resolving the contradiction between strength and moisture management.
Data Source
Figure 1~2
AI summary
The multi-component yarn is formed using synthetic textured filament yarn containing two components of a spin-rotated staple fiber yarn, where one of the components is an air blow-textured filament yarn. The components exhibit comparable fineness and structure within predetermined limits. The components of similar optical characteristics are twisted with one another by production of a twisted yarn with the staple fiber yarn. The staple fiber yarn is a tencel(RTM: cellulose fiber) yarn or contains tencel(RTM: cellulose fiber) yarn.