Proliferated 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
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Solution Overview
Problem
Cotton-synthetic hybrid textiles face limitations in thread count due to fine synthetic yarns breaking in loom apparatuses, leading to low quality and comfort, with manufacturers resorting to deceptive practices like counting twisted yarns multiple times, which is considered deceptive by regulatory bodies.
Innovation Solution
A method involving the formation of a multi-pick yarn package by twisting and detwisting synthetic yarns to create a low stability interlacing, applying uniform air pressure, and winding them onto a spool to enable simultaneous insertion in a single pick event of a loom apparatus, allowing for higher thread counts without yarn dissociation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fine synthetic yarns are used to increase thread count, then thread count and comfort are improved, but yarn reliability deteriorates due to breaking in loom apparatuses
Solution Approach 1:
The yarn is segmented into multiple fine filaments (e.g., 10-30 filaments per yarn) that are bundled together. Each filament is thin enough to contribute to high thread count, while the bundle structure provides collective strength to prevent breaking during loom operation.
Solution Approach 2:
The invention uses composite construction by combining multiple synthetic filaments into a single yarn structure. This composite approach allows the yarn to exhibit both the fineness of individual filaments (for high thread count) and the strength of the bundled structure (for reliability during weaving).
2Quantity of substance
If twisted yarns are counted multiple times to claim high thread count, then advertised thread count increases, but manufacturing precision deteriorates due to deceptive practices
Solution Approach 1:
Instead of deceptively counting twisted yarns multiple times, the invention creates multiple distinct parallel yarns that are simultaneously inserted. Each yarn is a genuine, separate entity that can be accurately counted, eliminating the need for deceptive counting practices while achieving high thread count.
Solution Approach 2:
The invention transitions from the traditional single-yarn sequential insertion to multi-yarn simultaneous insertion. This dimensional change in the weaving process allows multiple yarns to be inserted together in a single pick event, enabling authentic high thread count without deception.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances thread count, durability, and comfort while avoiding deceptive practices, resulting in a higher quality textile with improved tensile strength and consumer satisfaction.
Implementation Method 1
a friction twisting unit to twist and detwist the filaments within the formed oriented yarn
Implementation Method 2
an intermingling jet to apply a uniform air pressure to the formed oriented yarn to provide a counter-twist to the friction twisting unit
Data Source
AI summary
A method and a system disclosed include drawing each of multiple synthetic yarns from a corresponding supply package to form an oriented yarn. Filaments within the oriented yarn are twisted and detwisted to provide texture thereto, to provide a low stability interlacing during weaving, and to intermingle the filaments, and a uniform air pressure is applied to the oriented yarn to provide a counter-twist. Also, a multi-pick yarn package is formed based on winding all formed oriented yarns, which serve as weft yarns forming adjacent substantially parallel yarns wound together, onto a spool. These weft yarns are simultaneously inserted in a single pick insertion event of a loom apparatus, and conveyed across a warp shed of the loom apparatus through a set of warp yarns. The set of warp yarns and the conveyed weft yarns are interlaced to produce an incremental length of a woven textile fabric.