Recycled Separable Multi-Filament Yarns for High-Count Woven Textiles
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Solution Overview
Problem
Conventional methods for manufacturing multi-ply separable textured yarns face issues of low productivity, high production costs, and poor capability to produce fine and ultra-fine denier yarns, while also relying on non-eco-friendly virgin polymers from crude oil sources.
Innovation Solution
A method involving the recycling of polymers to form separable interlaced filament yarns, which are then processed through a spinning unit and interlacing means to create multi-ply separable textured yarns with strong interlacing that remains intact during further processing and in the fabric, using parameters such as interlacing devices, filament type, and fluid pressure to ensure separability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture multi-ply separable textured yarns, then the process is established and reliable, but productivity is low and production costs are high
Solution Approach 1:
The invention divides the yarn structure into separable plies (first ply and second ply) with different filament compositions. This segmentation allows each ply to be manufactured independently using optimized parameters, then combined through controlled interlacing. The separable structure enables higher productivity by allowing parallel processing of different plies while maintaining cost efficiency through targeted material selection and processing optimization.
Solution Approach 2:
The invention uses composite filament structures within each ply, where the first ply contains filaments of a first polymer and the second ply contains filaments of a second polymer. This composite approach allows optimization of each polymer type for its specific function, improving overall productivity while reducing costs by selecting cost-effective polymer combinations that meet performance requirements.
2Productivity
If conventional methods are used to manufacture multi-ply separable textured yarns, then the process is established, but the capability to produce fine and ultra-fine denier yarns is poor
Solution Approach 1:
The invention applies local quality by assigning different filament deniers to different plies - the first ply can have fine denier filaments while the second ply has different denier specifications. This allows each ply to be optimized for its specific denier requirement, enabling production of fine and ultra-fine yarns without increasing overall process complexity, as each ply is processed independently with tailored parameters.
3Object-affected harmful factors
If virgin polymers from crude oil sources are used, then the material properties are consistent, but the environmental impact is negative
Solution Approach 1:
The invention changes the material parameter from virgin polymer to recycled polymer, maintaining reliability through controlled interlacing parameters and processing conditions. The specific interlacing settings ensure that recycled filaments achieve sufficient bonding to maintain yarn integrity and consistent properties, while significantly reducing environmental impact by utilizing post-consumer or post-industrial recycled materials.
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 output and capability, reduces production costs, and enables the production of high thread/yarn count woven textiles with eco-friendly recycled materials, while maintaining the separability of yarn plies, thus addressing the limitations of conventional methods.
Implementation Method 1
parameters for strong interlacing are number of interlacing devices, number of filaments in the yarn, type of the filament, denier of the yarn, speed of the yarn passing through the interlacing devices, number of jets in the interlacing devices, number of nozzles in said jet, diameter of nozzles, type of fluid passed through the nozzles of the jets for causing interlacing of filaments and pressure of the fluid
Implementation Method 2
melting recycled polymers and passing the polymer melt through a spinning unit to form a plurality of molten streams, and cooling the molten streams in a quenching zone to form plurality of polymer filaments
Implementation Method 3
cooling the molten streams in a quenching zone to form plurality of polymer filaments
Data Source
AI summary
A high thread/yarn count woven textile fabric (800) is provided. The high thread/yarn count woven textile fabric (800) includes a plurality of warps (810), and a plurality of wefts (820). The high thread/yarn count woven textile fabric (800) having 250 to 3000 picks per inch in the weft (820) which can be extended up to 6000. Further, at least two recycled separable multi-filament parallel yarn picks are woven in groups together in the weft (820). It is provided that the recycled separable multi-filament parallel picks are separable and distinguishable from other picks very clearly. Furthermore, a denier of the recycled separable multi-filament yarn is range from 5 to 50. Usually, the thread/yarn count of woven textile fabric (800) is in between 400 to 3000 which can go up to 6000.