Multi-Ply Separable Textured Yarn Manufacturing Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing multi-ply separable textured yarns face issues of low productivity and high production costs, particularly in producing low and ultra-low denier yarns, due to inefficiencies in the separability of filament yarns during processing and in fabric production.
Innovation Solution
A method involving passing polymer melt through a spinning unit to form molten streams, cooling them to form filaments, grouping them into yarns, and interlacing these yarns using an interlacing means to create separable interlaced filament yarns, which are then converged to form multi-ply separable interlaced filament yarns that retain interlacing during further processing and in fabric production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture multi-ply separable textured yarns, then production cost is reduced, but productivity is low and separability is poor
Solution Approach 1:
The patent applies segmentation by dividing the yarn structure into multiple separable plies that can be independently processed and then recombined. Each ply is treated as an independent unit that can be manufactured separately and later assembled into multi-ply yarns, improving productivity while maintaining separability for high thread count fabric production.
Solution Approach 2:
The patent implements preliminary action by pre-interlacing filaments within each ply before the final multi-ply assembly. This preliminary interlacing ensures that when plies are separated and recombined, the filaments within each ply maintain their structural integrity and interlacing properties, thereby improving separability and reducing manufacturing costs.
2Productivity
If multi-ply yarns are manufactured with high separability, then fabric production capability is improved, but interlacing retention during processing deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the interlacing characteristics within each ply versus between plies. Filaments within each ply are strongly interlaced to maintain structural integrity during processing, while plies themselves remain separable for high thread count fabric production. This localized differentiation of interlacing strength resolves the contradiction between separability and interlacing retention.
3Manufacturing precision
If ultra-low denier yarns are produced, then fabric quality is improved, but production efficiency deteriorates
Solution Approach 1:
The patent applies merging by combining multiple ultra-fine plies into multi-ply yarns to achieve the desired yarn fineness. Instead of producing single ultra-low denier yarns which is inefficient, the method combines several finer plies (e.g., multiple 10-denier plies to create equivalent 30-denier yarn) maintaining production efficiency while achieving the required fineness for high-quality fabric.
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 significantly increases production efficiency and reduces costs by enabling the production of high-quality multi-ply separable textured yarns with improved separability, allowing for the production of fine and ultra-fine denier yarns, and enhancing the capability to produce multiple plies without breaking other plies, thus overcoming conventional limitations.
Implementation Method 1
cooling them to form filaments
Implementation Method 2
cooling the molten streams in a quenching zone to form plurality of polymer filaments
Data Source
AI summary
A method of manufacturing multi-ply separable textured yarn, the method comprising, passing a multi-ply separable interlaced filament yarn through a texturizing unit to form a multi-ply separable draw textured yarn, wherein the multi-ply separable interlaced filament yarn is separable in to at least two separable interlaced filament yarn, wherein the interlacing of the filaments within each separable interlaced filament yarn is retained during further processing of the yarn to fabric and in the fabric.