Parallel Multi-Pick Weft Insertion for High Thread Count Textiles

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Solution Overview

Problem

Cotton-synthetic blends in textiles face limitations in thread count due to fine synthetic weft yarns breaking in loom apparatuses, leading to low quality and comfort, with manufacturers resorting to deceptive practices like counting twisted yarns separately, which is considered deceptive by regulatory bodies.

Innovation Solution

A method of simultaneously inserting multiple adjacent parallel polyester weft yarns during a single pick insertion event in a loom apparatus, using a multi-pick yarn package, to increase thread count while maintaining the feel and absorbency of cotton, with the yarns being wound in a parallel and adjacent configuration to prevent breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If fine synthetic weft yarns are used to increase thread count, then thread count increases, but the yarns break in loom apparatus

Engineering Contradiction:

Improvethread countVSAvoidyarn strength

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent combines multiple fine synthetic weft yarns (e.g., two 20-denier yarns) into a single bundled structure that is inserted through the loom as one unit. This merging approach allows the use of fine yarns to achieve high thread count while the bundled structure provides the strength needed to prevent breakage during weaving operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention segments the weft insertion process by treating multiple adjacent yarns as a single insertable unit. The yarns are positioned in parallel adjacency and fed together through the pick insertion apparatus, allowing them to be inserted simultaneously as one group rather than individually, thus maintaining both fineness and strength.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If twisted yarns are used to claim high thread count, then advertised thread count increases, but the textile quality does not match consumer expectations

Engineering Contradiction:

Improvethread countVSAvoidtextile quality

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

Instead of twisting yarns together to achieve high thread count (the conventional deceptive approach), the patent inverts the approach by placing multiple yarns in parallel adjacency and inserting them simultaneously as separate but adjacent strands. This honest approach achieves high thread count through quantity of parallel yarns rather than through twisting, delivering both high thread count and satisfactory textile quality.

Inventive Principle:

Principle #13The other way round (Inversion)

3Quantity of substance

If multiple yarns are inserted simultaneously, then thread count increases, but the loom apparatus complexity increases

Engineering Contradiction:

Improvethread countVSAvoidloom apparatus complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent adapts existing pick insertion apparatus to perform a new function: inserting multiple parallel yarns simultaneously. By modifying the accumulator and guide components to handle bundled yarns, the existing loom infrastructure is utilized without requiring completely new complex mechanisms, thus achieving high thread count with minimal increase in apparatus complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10443159B2Proliferated thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package

Publication Date: 2019.10.15 AAVN

AI summary

Disclosed are a method, a device and/or a system of proliferating a thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package. In one or more embodiments, multiple texturized polyester weft yarns of denier between 15 and 65 are wound on a single bobbin in a parallel adjacent fashion such that they may be fed into an air jet pick insertion apparatus and/or a rapier pick insertion apparatus of an air jet loom to weave a textile that has between 90 to 235 ends per inch cotton warp yarns and between 100 and 1410 polyester weft yarns.