Textured Spun Yarn Reverse Twisting for Bulky Soft Fabrics
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Solution Overview
Problem
Existing methods for manufacturing bulky yarns and fabrics using cellulosic fibers are complex, time-consuming, and costly, and often fail to provide sufficient bulkiness and are limited to synthetic fibers, while methods for natural fibers like cotton are inefficient and require multiple treatment processes.
Innovation Solution
A textured spun yarn is created by starching and drying a single spun yarn, then twisting it in the opposite direction by 1.6 to 3 times its original twist, allowing for the removal of the starch agent to produce a lightweight, soft, and heat-insulating fabric without the need for water-soluble yarns or harsh chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If starching process, liquid ammonium treatment, warm or hot treatment, reverse twisting with water-soluble yarn, and dissolving of water-soluble yarn are performed to obtain bulky yarn, then bulkiness is improved, but process complexity increases and manufacturing time increases
Solution Approach 1:
The invention extracts and eliminates the water-soluble yarn component from the conventional multi-step process. Instead of using water-soluble yarn as a temporary support that must be dissolved, the patent applies starching directly to the hard twist yarn, then uses liquid ammonium treatment to remove the starch, achieving bulkiness without requiring dissolution steps or water-soluble yarn components.
Solution Approach 2:
The invention performs preliminary starching of the hard twist yarn before twisting with the water-soluble yarn. The starch is applied in advance to create a bulky structure, and then the water-soluble yarn is removed via liquid ammonium treatment, allowing the bulkiness to be established before final fabric formation.
2Volume of moving object
If starching process, liquid ammonium treatment, warm or hot treatment, reverse twisting with water-soluble yarn, and dissolving of water-soluble yarn are performed to obtain bulky yarn, then bulkiness is improved, but manufacturing time increases
Solution Approach 1:
The invention extracts and eliminates the water-soluble yarn component from the conventional multi-step process. Instead of using water-soluble yarn as a temporary support that must be dissolved, the patent applies starching directly to the hard twist yarn, then uses liquid ammonium treatment to remove the starch, achieving bulkiness without requiring dissolution steps or water-soluble yarn components.
Solution Approach 2:
The starch agent serves as a temporary, disposable bulk-forming component that is applied, allows the yarn structure to be formed, and then easily removed via liquid ammonium treatment. This temporary starch coating provides the necessary bulkiness during manufacturing and is then discarded, replacing the more time-consuming water-soluble yarn dissolution process.
3Shape
If water-soluble yarn is used in composite twisted yarn to achieve reverse twist and bulkiness, then airy touch and texture are improved, but cost increases
Solution Approach 1:
The starch agent serves as a temporary, disposable bulk-forming component that is applied, allows the yarn structure to be formed, and then easily removed via liquid ammonium treatment. This temporary starch coating provides the necessary bulkiness during manufacturing and is then discarded, replacing the more time-consuming water-soluble yarn dissolution process.
Solution Approach 2:
The invention changes the chemical parameter of the bulk-forming agent from water-soluble yarn (requiring dissolution in water) to starch (removed by liquid ammonium treatment). This parameter change in the removing agent allows for easier and more cost-effective removal while achieving the same airy texture and bulkiness effects.
4Volume of moving object
If false twisting process and crimping process are performed on yarn to give bulkiness, then bulkiness is improved, but applicability is limited to synthetic fibers
Solution Approach 1:
The invention changes the chemical parameter of the bulk-forming agent from water-soluble yarn (requiring dissolution in water) to starch (removed by liquid ammonium treatment). This parameter change in the removing agent allows for easier and more cost-effective removal while achieving the same airy texture and bulkiness effects.
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, excellent in heat-insulating and anti-pilling properties, sustainable, and rapid-drying, with improved weaving and knitting properties, and can be applied to various fiber types including natural and synthetic fibers.
Implementation Method 1
a textured spun yarn obtained by twisting a starched and dried single spun yarn in an opposite direction to a twisting direction of a single spun yarn
Implementation Method 2
wherein the starch agent is dissolved and removed in water from the textured spun yarn or from a woven or knitted fabric obtained by performing weaving or knitting using the textured spun yarn
Data Source
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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.