Separable Multi-Ply Textured Yarn With Retained Interlacing
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Solution Overview
Problem
Conventional methods for manufacturing multi-ply separable textured yarns face issues of low productivity, high production cost, and inability to produce fine and ultra-fine denier yarns, with the problem of non-separable plies leading to inefficient industrial processes.
Innovation Solution
A method involving the formation of separable interlaced filament yarns by passing polymer melt through spinning and quenching to create filaments, followed by interlacing to form multi-ply yarns that retain interlacing during further processing, using controlled interlacing jets to maintain separability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture multi-ply separable textured yarns, then the process is simple, but productivity is low and production cost is high
Solution Approach 1:
The patent applies segmentation by dividing the yarn into multiple separate filaments that are interlaced but remain individually separable. Each filament is processed independently through the spinning and texturizing units, then recombined through controlled interlacing. This allows parallel processing of multiple filaments simultaneously, dramatically increasing productivity while maintaining separability for later unplying operations.
Solution Approach 2:
The patent implements preliminary action by performing interlacing of filaments during the initial spinning stage before texturizing. This preliminary interlacing structure is designed to be strong enough to withstand subsequent texturizing processes but weak enough to allow easy separation later. By establishing the separable structure early, the system avoids complex post-processing steps and improves overall production efficiency.
2Manufacturing precision
If conventional manufacturing methods are used, then equipment is simple, but inability to produce fine and ultra-fine denier yarns occurs
Solution Approach 1:
The patent applies local quality by providing different treatments to different filaments within the same yarn structure. Each filament can have controlled denier variations, and the interlacing density can be locally adjusted to maintain structural integrity while allowing fine denier control. This enables production of fine and ultra-fine denier yarns with precise manufacturing precision while maintaining versatility in yarn type production.
3Strength
If plies are made non-separable to improve structural integrity, then yarn strength increases, but industrial process efficiency decreases
Solution Approach 1:
The patent implements dynamics by creating an adaptive interlacing structure that exhibits different properties under different conditions. During processing and normal use, the interlaced structure provides sufficient strength and stability. However, under specific unplying conditions (such as mechanical separation or chemical treatment), the structure dynamically transitions to allow easy separation of plies. This dynamic behavior resolves the contradiction between maintaining strength and enabling efficient separation for industrial processing.
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 method enhances production efficiency, reduces costs, and enables the production of fine and ultra-fine denier yarns by ensuring separability of plies throughout processing and in the finished fabric, thereby improving industrial productivity and reducing costs.
Implementation Method 1
passing a polymer melt through a spinning unit to form a plurality of molten streams
Implementation Method 2
cooling the molten streams in a quenching zone to form plurality of polymer filaments
Implementation Method 3
passing the yarn through an interlacing means to interlace the filaments within the yarn
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 10 of the filaments within each separable interlaced filament yarn is retained during further processing of the yarn to fabric and in the fabric.