Spun-Dyed Black Polyamide Yarn for Soft Hosiery
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Solution Overview
Problem
Conventional polyamide yarns used in hosiery products face challenges in achieving a soft texture, durability, and a dark black color while maintaining reasonable market prices, as they often result in a whitish appearance due to light reflections, pilling, and increased costs, especially when attempting to develop a dark black color.
Innovation Solution
A spun-dyed black polyamide yarn with 1% to 5% carbon black content, an average particle diameter of 1 µm to 20 µm, and a single fiber fineness of 0.8 dtex to 2 dtex, combined with a false-twisted yarn and covered elastic yarn, to create hosiery products that can develop a dark black color while maintaining softness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the single fiber fineness of polyamide yarns is reduced to achieve softness, then the soft texture is improved, but the yarn becomes whitish due to irregular light reflections and fails to develop a dark black color
Solution Approach 1:
The invention changes the particle size parameter of carbon black from conventional small particles to specifically controlled particles with average diameter of 1-20 μm. This parameter change allows the carbon black to effectively absorb light and develop dark black color in ultra-fine yarns without causing whitish appearance, while maintaining the soft texture achieved through reduced fiber fineness
Solution Approach 2:
The invention uses composite materials by combining polyamide with carbon black particles of specific size range (1-20 μm) at controlled content (1-5% by mass). This composite structure enables the yarn to simultaneously achieve softness from ultra-fine fibers and dark black color from the carbon black particles, resolving the contradiction between soft texture and color development
2Strength
If the single fiber fineness is reduced to improve softness, then the soft texture is enhanced, but durability decreases due to filament breakage and pilling
Solution Approach 1:
The carbon black particles (1-20 μm) act as reinforcing fillers in the polyamide matrix, creating a composite material that enhances durability. The particles strengthen the ultra-fine fibers, reducing filament breakage and pilling while maintaining the soft texture from reduced fineness
Solution Approach 2:
The carbon black particles are distributed throughout the yarn structure to provide localized reinforcement at critical points where stress concentrates, thereby improving overall durability without affecting the softness of the bulk material
3Illumination intensity
If carbon black is added to polyamide yarn to develop dark black color, then the color developing property is improved, but production cost increases due to removal of sea component
Solution Approach 1:
The invention changes the particle size parameter of carbon black to 1-20 μm, which are particles that can be directly incorporated into the polyamide during spinning without requiring subsequent removal of sea components. This parameter change eliminates the need for expensive post-processing steps while achieving dark black color
Solution Approach 2:
The invention extracts or eliminates the need for sea component removal by using carbon black particles of appropriate size that can be directly spun into the yarn structure. This removes the problematic step of eluting PE with toluene, reducing production cost and complexity
4Strength
If sea component removal is performed to obtain ultra-fine yarn, then the soft texture is improved, but production cost increases and elastic yarn deteriorates due to solvent exposure
Solution Approach 1:
The invention extracts or eliminates the need for sea component removal by directly incorporating carbon black particles into the polyamide yarn during the spinning process. This removes the problematic step of eluting PE with toluene, reducing production cost and preventing damage to elastic core yarns
Solution Approach 2:
The carbon black particles are incorporated into the polyamide matrix during the initial spinning process, before any potential sea component removal would occur. This preliminary incorporation eliminates the need for subsequent removal steps and protects the elastic yarn from solvent exposure
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 solution enables the production of hosiery products with a soft texture, dark black color, and improved durability, reducing pilling and yarn breakages, while also optimizing production costs by eliminating the need for a dyeing step and minimizing environmental impact.
Implementation Method 1
capable of developing a dark black color
Data Source
AI summary
A spun-dyed polyamide yarn wherein carbon black produced by a furnace method and having an average particle diameter of µm to 20 µm is contained in an amount of 1% to 5% by mass in a polyamide and which has a single fiber fineness of 0.8 dtex to 2 dtex; a false-twisted yarn produced by falsely twisting the spun-dyed black polyamide yarn; a covered elastic yarn, in which the spun-dyed black polyamide yarn or the false-twisted yarn is used as a covering yarn; and hosiery, in which at least one of the spun-dyed black polyamide yarn, the false-twisted yarn and the covered elastic yarn is used in part of a leg portion. Provided are stockings or tights which have a soft texture and are capable of developing a dark black color.