Plied Yarns from Cotton and Modal for Linting Control
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Solution Overview
Problem
Existing terry fabric manufacturing methods rely on intimate blending of fibers, which can result in inconsistent hand feel and linting properties, limiting flexibility in achieving desired properties like high absorbency, quick drying, and softness, and low linting properties, and the manufacturing process lacks flexibility in adjusting the yarns' composition.
Innovation Solution
A method of forming a plied yarn using two different yarns, comprising a first yarn of 100% cotton and a second yarn of a second yarn, where the yarns are twisted in a direction opposite to the singles-yarn twist to give a torque-balanced yarn, with a twist multiplier of 2.5 to 3.8 and a yarn ply twist per inch between 4 and 7, and the yarns are not intimately blended.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If intimate blending of fibers is used in terry fabric manufacturing, then fiber uniformity is improved, but hand feel consistency and linting properties deteriorate
Solution Approach 1:
The invention divides the yarn structure into separate plied yarns, each containing fibers of a specific type (cotton or synthetic), rather than intimately blending all fibers together. This segmentation allows each yarn to maintain consistent fiber composition and properties, while the plied structure combines the benefits of different fiber types in the final fabric.
2Ease of manufacture
If intimate blending of fibers is used, then manufacturing process simplicity is improved, but flexibility in adjusting yarn composition deteriorates
Solution Approach 1:
The invention enables dynamic adjustment of yarn composition by varying the ratio, size, and type of plied yarns used in the fabric construction. Manufacturers can easily adjust the composition by changing the number of cotton or synthetic plies, their relative sizes, or their arrangement in the fabric structure, providing flexibility without complicating the manufacturing process.
3Reliability
If high absorbency is achieved through fiber selection, then absorbency property is improved, but drying speed deteriorates
Solution Approach 1:
The invention applies local quality by using different fiber types in different plied yarns within the same fabric. Cotton plies provide high absorbency in areas requiring moisture uptake, while synthetic plies provide quick drying properties in areas requiring rapid moisture evaporation. This allows the fabric to exhibit both high absorbency and quick drying characteristics in different locations.
4Reliability
If softness is achieved through fiber selection and blending, then hand feel is improved, but linting properties deteriorate
Solution Approach 1:
The invention uses composite materials by combining cotton and synthetic fibers in a plied yarn structure. The cotton provides softness and comfort in contact with the skin, while the synthetic fibers contribute to reduced linting and improved durability. The plied structure ensures that the beneficial properties of each fiber type are preserved and work together synergistically.
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
The method produces a yarn with enhanced properties, including low linting, high absorbency, and quick drying, while maintaining the individual characteristics of each fiber, providing flexibility in manufacturing and improved hand feel.
Implementation Method 1
The second yarn is manufactured as a separate yarn with an air vortex spinning process
Implementation Method 2
the yarns are twisted in a direction opposite to the singles-yarn twist to give a torque-balanced yarn
Data Source
AI summary
Plied yarns and methods of constructing plied yarns from two different yarns, manufactured using different fibers wherein the plied yarns possess enhanced properties. The yarns developed and described herein are plied yarns, rather than, and in direct contrast to intimately blended yarns. Examples of the fibers and/or yarns utilized in forming the yarns of different fibers described herein, include but are not limited to 100% cotton, Modal, and Lyocell. The yarns described herein can be used for various end uses, including but not limited to formation of terry fabric for use in towels, robes, apparel, and the like.