Spiral Yarn Structure Reducing Textile Shrinkage and Torque
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Solution Overview
Problem
Conventional textile manufacturing using twisted yarns faces challenges with high shrinkage, torque, and skew issues, particularly in lightweight fabrics made from cotton or cellulose, which are difficult to control and result in post-processing problems such as uneven quality and increased labor due to mechanical limitations and torque generated in loom/knit machines.
Innovation Solution
The development of a spiral yarn structure comprising a core yarn enclosed by a cover yarn formed by staple fibers, with a wrap yarn wrapping the cover yarn at a twist factor ≤3, which reduces twist, torque, and shrinkage, and is manufactured using a ring spinning machine with a drafting assembly and guiding wheel to form a textile with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional twisted yarns are used in lightweight textiles, then the textile can be made with cotton or cellulose materials, but the shrinkage reaches 8%-15%, torque exceeds 3%, and skew reaches 25-30%
Solution Approach 1:
The yarn is divided into multiple independent components: core filaments (providing strength), cover fibers (providing appearance and encasement), and wrap filaments (providing spiral structure). This segmentation allows each component to perform its specific function independently, resulting in a yarn structure that maintains lightweight properties while controlling shrinkage and torque through the spiral configuration rather than conventional twisting
Solution Approach 2:
The yarn structure employs a nested configuration where core filaments are enclosed by cover fibers, which in turn are wrapped by wrap filaments in a spiral pattern. This nested doll structure allows the inner core to provide tensile strength while the outer layers control the yarn's dimensional stability, reducing shrinkage and torque without adding significant weight
2Manufacturing precision
If elastomeric yarns (Spandex) are used to improve shrinkage and torque, then these parameters are slightly improved, but skew remains at 25-30% and total weight of the cloth increases
Solution Approach 1:
The invention changes the fundamental parameter of yarn construction from conventional twisted structures to a spiral configuration with wrap filaments at specific angles. This parameter change in the yarn architecture provides shrinkage and torque control through the geometric spiral structure rather than relying on elastomeric materials, thereby avoiding the weight penalty while maintaining dimensional stability
3Ease of manufacture
If conventional twisted yarns are used, then textile can be manufactured with standard processes, but post-processing is required including loosening, pre-shrinking, and washing to control skew and shrinkage
Solution Approach 1:
The spiral yarn structure is designed with pre-determined geometric parameters during manufacturing, including the wrap filament angle and tension settings, so that the yarn inherently possesses the desired dimensional stability. This preliminary action embeds the shrinkage and skew control characteristics into the yarn structure itself, eliminating the need for subsequent loosening, pre-shrinking, and washing operations
4Strength
If high twist is applied to conventional yarns to maintain strength, then yarn strength is maintained, but torque and skew increase significantly
Solution Approach 1:
The invention replaces linear twisting with a spiral/curved configuration of wrap filaments around the core and cover layers. This curved geometric arrangement provides mechanical strength through the spiral architecture rather than through tight twisting, thereby maintaining yarn strength while significantly reducing the torque and skew that result from conventional high-twist constructions
Data Source
AI summary
A spiral yarn structure includes a core yarn comprising at least one core filament which is a filament fiber of 5-25D, a cover yarn comprising a plurality of cover fibers formed by stretching roves having a count ranging from 0.5 Ne to 2.0 Ne, wherein the cover fibers encloses the core yarn, and a wrap yarn wrapping the cover yarn at a twist factor K≤3, wherein the wrap yarn comprises at least one wrap filament which is a filament fiber of 5-25D, and the at least one wrap filament wraps an outer side of the cover yarn at an inclined angle to form the spiral yarn structure having a count ranging from 40 Ne to 80 Ne.