Twisted Organic Synthetic Yarn Moisture Management

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Solution Overview

Problem

Blended yarns face challenges in controlling the placement of staple fibers, leading to inconsistent material composition and inhibited performance characteristics, particularly in moisture management, durability, and dimensional stability, due to their density and lack of air space.

Innovation Solution

Twisting organic and synthetic yarns together at specific angles and twist speeds to create a yarn with controlled surface area ratios and air spaces, enhancing tensile strength, moisture management, and dimensional stability, while allowing for tailored performance attributes in knitted articles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If organic and synthetic staple fibers are blended together to form blended yarns, then the yarn contains both fiber types, but the placement of staple fibers cannot be controlled leading to inconsistent material composition and inhibited performance characteristics

Engineering Contradiction:

Improvematerial composition consistencyVSAvoidfiber placement control

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The invention divides the yarn structure into distinct segments - organic yarn segments and synthetic yarn segments - that are twisted together. This segmentation allows each fiber type to maintain its own integrity and placement characteristics, solving the problem of uncontrolled fiber mixing while achieving consistent material composition in the final blended yarn product.

Inventive Principle:

Principle #1Segmentation

2Strength

If blended yarns are made with high density to improve strength, then tensile strength increases, but air space is reduced leading to poor moisture management

Engineering Contradiction:

Improvetensile strengthVSAvoidmoisture management

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention applies local quality by creating yarns with non-uniform density distribution - denser regions provide strength while less dense regions with more air space provide moisture management. The twisted construction allows different sections of the yarn to have different characteristics, with organic fibers providing moisture-wicking channels and synthetic fibers providing structural strength.

Inventive Principle:

Principle #3Local quality

3Reliability

If organic yarn and synthetic yarn are twisted together at high twist angles to improve surface area ratio control, then moisture management improves, but yarn strength may be reduced

Engineering Contradiction:

Improvemoisture managementVSAvoidyarn strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention utilizes parameter changes by varying the twist angle and twists per inch to optimize the balance between moisture management and strength. By controlling these twist parameters, the yarn achieves sufficient surface area exposure for moisture wicking while maintaining adequate inter-fiber bonding for tensile strength. The specific parameter ranges (twist angles of 15-65 degrees, 10-35 twists per inch) represent optimized values that resolve this contradiction.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11639564B1Twisted yarns and methods of manufacture thereof

Publication Date: 2023.05.02 WETSOX LLC

AI summary

A yarn is produced by twisting an organic yarn and a synthetic yarn. The organic and synthetic yarns and twisting processes thereof may be selected to produce a twisted yarn with enhanced performance characteristics such as moisture management, abrasion resistance, and refit. The twisted yarn may be knitted into articles of clothing such as socks.