Textured Spun Yarn Reverse Twisting Without Water-Soluble Yarn
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Solution Overview
Problem
Existing methods for manufacturing bulky yarns and woven or knitted fabrics from cellulosic fibers are complex, time-consuming, and costly, and often fail to provide sufficient bulkiness and softness, especially when using cotton fibers, due to the requirement of multiple treatment processes and the use of water-soluble yarns.
Innovation Solution
A textured spun yarn is created by starching and drying a single spun yarn, then twisting it in the opposite direction by 1.3 to 3 times the original twist, without using a water-soluble yarn, to produce a fabric that is lightweight, soft, and excellent in heat-insulating and anti-pilling properties, with the starch agent being removable in water to enhance bulkiness and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If starching process, liquid ammonium treatment, warm or hot treatment, reverse twisting with water-soluble yarn, and dissolving/removal of water-soluble yarn are performed to obtain bulky yarn, then bulkiness is improved, but process complexity increases and manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the water-soluble yarn component from the conventional composite twisted yarn structure, replacing it with a single spun yarn that undergoes starching and reverse twisting. This extraction simplifies the process by removing the need to introduce and subsequently remove water-soluble yarn, while still achieving the desired bulkiness through the starching-induced reverse twist mechanism
Solution Approach 2:
The invention changes the physical and chemical parameters of the single spun yarn by applying starching treatment and controlled reverse twisting. The starching modifies the yarn's mechanical properties, allowing it to maintain the reverse twist structure, which in turn creates the bulkiness when the starch is removed or hydrolyzed during washing
2Shape
If water-soluble yarn is used in composite twisted yarn to achieve bulking effect, then bulkiness is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive water-soluble yarn with a disposable starching agent that serves its purpose temporarily during processing. The starch is applied, provides the necessary structural support for reverse twisting, and then is easily removed through washing or hydrolysis, leaving the desired bulkiness without the need for costly water-soluble yarn materials
3Shape
If multiple treatment processes are performed to manufacture bulky woven or knitted fabric, then bulkiness is improved, but time consumption increases
Solution Approach 1:
The invention merges multiple separate treatment processes into a integrated sequence: starching is applied during or before the twisting process, and the reverse twisting is performed as part of the yarn formation rather than as a separate post-treatment. The removal of starch and achievement of bulkiness occurs during the normal washing process of fabric production, eliminating the need for separate treatment steps and reducing overall time consumption
4Device complexity
If water-soluble yarn is constrained in doubled yarn and dissolved/removed in constrained state, then bulkiness is limited, but process simplicity is maintained
Solution Approach 1:
The invention applies preliminary starching treatment to the single spun yarn before twisting, which modifies the yarn's properties to allow for effective reverse twisting. This preliminary action ensures that when the yarn is reversely twisted and subsequently washed, the starch removal occurs more effectively, enabling greater bulkiness development compared to conventional methods where water-soluble yarn is constrained throughout the process
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 results in fabrics that are lightweight, soft, and excellent in heat-insulating and anti-pilling properties, with improved sustainability and air permeability, and eliminates the need for water-soluble yarns, reducing costs and simplifying the manufacturing process while maintaining excellent texture and bulkiness.
Implementation Method 1
a textured spun yarn obtained by twisting a starched and dried single spun yarn
Implementation Method 2
with the starch agent being removable in water to enhance bulkiness and texture
Data Source
AI summary
Provided are a textured spun yarn (A0) obtained by twisting a starched and dried single spun yarn in the opposite direction to the twisting direction of the single spun yarn by the number of twists which is 1.3 to 3 times the number of twists of the single spun yarn, a textured spun yarn (A1) obtained by removing a starch agent in water from the textured spun yarn, a woven or knitted fabric obtained by dissolving and removing the starch agent in water from a woven or knitted fabric manufactured using the textured spun yarn (A0), and a woven or knitted fabric manufactured using the textured spun yarn (A1), and methods of manufacturing them.