Low Temperature Fiber Spinning and Textile Finishing Method

Methods for spinning, weaving, and finishing fabric and/or cloth containing cotton fibers are disclosed. The methods of the invention are performed at lower ambient, solution and/or working temperatures than is previously known in the art. The reduced temperature processing improves various qualities of the resulting textile products and fabrics and lowers costs of operating the processing facility.

BACKGROUND OF THE INVENTION

Embodiments of the present invention generally relate to methods for spinning textile fibers at low temperatures and finishing textiles at low temperatures. Said finishing includes low-temperature bleaching, low-temperature mercerizing, and/or low-temperature dyeing steps. The preferred fiber for the methods of the instant is cotton, but other textile fibers may also be used. The textiles may be composed of a single type of fiber, or may be a blend of fibers, preferably including cotton.

Processing raw fibers into usable textiles requires multiple steps. First, the raw fiber must be spun into usable thread or yarn, referred to herein as the “spinning step”. Then the thread or yarn is woven into a textile, referred to herein as the “weaving step”. Finally, the textile is finished. Each of these three steps includes multiple sub-steps, referred to herein as the “finishing step”. The methods of this invention are improvements to the previously-known spinning and finishing steps.

The previously-known implementation of the spinning step generally includes blowing and cleaning, carding, drawing, simplex, spinning, and winding sub-steps. Some of these sub-steps may be omitted when using certain fibers or when producing certain types of thread or yarn. Spinning certain fibers and/or producing certain other types of thread and/or yarn may require additional substeps.

The previously-known implementation of the finishing step generally includes greige batching, singeing, desizing, scouring, bleaching, width setting, mercerizing, dyeing, finishing and sanforizing sub-steps. Some of these sub-steps may be omitted when using certain fibers or when the finished product is to have certain characteristics. Some additional sub-steps may be included when using certain fibers or when the finished product is to have certain characteristics.

The finishing sub-steps are used to give the finished textile desired finish, strength, and/or other qualities. The finishing sub-steps often rely on the completion of a previous sub-step, for example, dyeing a textile an even and vibrant color requires it first to be bleached to an even white.

Certain sub-steps are discussed further herein. Other than the modifications disclosed as part of an embodiment of the instant invention, when a sub-step is referred to herein, it is the form of the sub-step that is well-known in the textile arts.

Generally, the previously known and preferred modes of performing the spinning step and most sub-steps of the finishing step, particularly the bleaching step, mercerizing step, and/or the dyeing step are performed at a temperature significantly above the standard “room temperature” of approximately 21 degrees Celsius (71 degrees Fahrenheit). (Temperatures in degrees Celsius are hereinafter given as “C” and those in Fahrenheit as “F.”) All temperature values given herein are intended to represent ranges and no particular value given is meant to exclude substantially similar temperatures in a range around the temperature given.

As an example, the spinning step is conventionally performed at a temperature of approximately 40-45 C. Certain sub-steps of the finishing step are conventionally performed at even higher temperatures. For example, conventional bleaching is performed at approximately 100-102 C, conventional mercerizing is performed at approximately 60-90 C, and conventional dyeing is performed at 100-160 C, depending on the dyeing process used.

The instant invention is directed to, inter alia, performing the spinning step and certain sub-steps of the finishing step, namely bleaching, mercerizing and dyeing, at substantially lower temperatures than conventional in the textile arts.

BRIEF SUMMARY OF THE INVENTION

In one embodiment of a method of the instant invention, cotton is spun at a reduced temperature than the standard for industrial cotton spinning. The cotton may also be spun at higher revolutions per minute (“RPM”) than is standard for industrial cotton processing.

In another embodiment of a method of the instant invention, textiles containing cotton are finished in a process including bleaching, mercerizing, and/or dyeing at a reduced temperature as compared to the standard temperatures for performing bleaching, mercerizing, and/or dyeing.

In a third embodiment of the instant invention, the first two embodiments are performed in sequence: cotton is spun as described, is then woven into a textile and that textile is finished, said finishing including bleaching, mercerizing, and/or dyeing at a reduced temperature as compared to the standard temperatures for performing bleaching, mercerizing, and/or dyeing.

Performing these steps at reduced temperatures has multiple benefits. Energy is saved because the spinning room, bleaching liquor, mercerizing solution, and dye do not require heating. The comfort and safety of workers is improved due to cooler ambient temperatures and absence of dangerously hot liquids. Additionally, there are significant improvements to the quality of thread and textile produced by the low-temperatures processes, as discussed more fully herein.

Where a term is provided in the singular, the inventors also contemplate aspects of the invention described by the plural of that term. As used in this specification and in the appended claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise, e.g., “a machine” may include a plurality of machines. Thus, for example, a reference to “a method” includes one or more methods, and/or steps of the type described herein and/or which will become apparent to those persons skilled in the art upon reading this disclosure.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, constructs and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety. Where there are discrepancies in terms and definitions used in references that are incorporated by reference, the terms used in this application shall have the definitions given herein.

“Ambient temperature” as used herein refers to the approximate average and standard air temperature of the enclosure or area in which a given process is performed. The materials, machine, equipment, solution, and/or atmosphere immediately around a given machine or process may be outside a range given for ambient temperature without changing the ambient temperature.

Disclosed herein are methods for spinning cotton into thread and/or yarn at reduced ambient temperatures and finishing woven textiles comprised at least partially of cotton at reduced temperatures. As part of this method, thread, yarn, and or textiles with improved properties are produced under safer conditions and at reduced expense.

The instant method may be performed in a single facility, wherein cotton is processed from raw cotton to finished textile, or may be performed at separate facilities, wherein raw cotton is processed and spun into thread and/or yarn at a first facility, yarn is woven into textiles at a second facility, and/or the textiles are finished at a third facility. It is preferred that the method of the instant invention be performed at a single facility.

The preferred embodiment includes both spinning cotton and finishing textiles. However, in certain embodiments of the instant invention, only the low-temperature spinning is performed. In other embodiments, only the low-temperature finishing steps are performed.

The cold spinning process100of one method embodying the instant invention, as depicted inFIG. 1, includes a blowing and cleaning step110, a carding step120, a drawing step130, a spinning step140, and, in some embodiments, a weaving step150. The aforementioned steps are, generally, performed as is well-known in the art, with the exception of the ambient temperature and, with respect to the spinning step140, the spinning speed.

In the instant invention, the blowing and cleaning step110, carding step120, drawing step130, and spinning step140are all performed at an ambient temperature of 25-30 C, a temperature substantially less than the ambient temperature of 40-45 C which is standard in the art for performing the corresponding steps of the standard spinning process. This reduced temperature permits spinning the fiber into yarn and/or thread at higher revolutions per minute without a corresponding increase in breakage of the cotton.

The blowing and cleaning step110, carding step120, and drawing step130of the cold spinning process100are performed as are standard in the art with the exception of the ambient temperature. Any machine or equipment known in the art for performing said steps may be used to perform said steps as part of the method of the instant invention. The steps may be performed in separate rooms of a facility or may be performed on machines disposed in a single room of a spinning facility, which may be part of a larger spinning, weaving, and/or finishing facility. Other fabric processes, such as embroidering, may also be performed in such a facility.

The blowing and cleaning step110processes raw and/or unspun cotton105into opened clean fibers and/or tufts as is known in the art. The carding step120completes the cleaning of the cotton and separates and aligns the fibers as is known in the art. The drawing step130evens the lengths of the fibers as is known in the art.

In the spinning step140, the cotton fibers are spun into thread and/or yarn145on an open-ended spinning machine350. In the instant invention, the spinning step140is preferably performed at 25-30 degrees Celsius and is performed at up to 150,000 RPM, substantially faster than standard spinning processes in the art, which are performed at 20,000 RPM. Additionally, the spinning step140does not require the generally-required rewinding process of most spinning processes known in the art.

The increased revolutions per minute used in the spinning step140combined with the reduced ambient temperature provides multiple benefits as compared with the conventional process as known in the art. In particular, the yield of the spinning process100is 5% greater than that of the conventional process: the instant spinning process100has an approximately 88% yield by weight as opposed to a yield of 82-84% by weight in the conventional process. Yarn145produced using the instant spinning process100also has a reduced imperfection index (“IPI”) and reduced hairiness as compared to conventionally produced yarns.

A variety of weights and types of yarns and/or threads145can be produced in the spinning process100of the instant method including, without restriction, 20/1 yarn for weaving. TABLE 1, below, lists the characteristics of 20/1 yarn produced using the conventional process and the method of the instant invention.

Once the thread and/or yarn145is spun it may be sold and/or stored as-is. It may also be woven in the same or another facility in a weaving step150. Preferably, the weaving step150is performed at an ambient temperature of 25-30 C, a relative humidity of 75%-78%, and otherwise performed as is standard and well-known in the industry. Processing at a lower temperature as in the other steps of the spinning process100of the instant invention allows the weaving step150to be performed in the same facility as the other steps of the spinning process100and has similar benefits to the working environment. Additionally, less fluff is produced as compared to conventional weaving processes performed at higher ambient temperatures and/or using thread and/or yarn produced using conventional processes. The reduction in fluff improves cleanliness of the spinning and weaving facility and reduces the health and safety risks related to increased fluff in such a facility, including, without restriction, fire risks.

Following the weaving step150, the fabric160woven in the weaving step150may be finished using any finishing process known in the art. Preferably, however, the fabric160woven in the weaving step150is then finished using the cold-finishing process200of the instant invention as shown inFIG. 2. The full preferred method of the instant invention, including the cold spinning process100including the weaving step150, followed by the cold finishing process200, is shown inFIG. 3. The cold-finishing process200of the instant invention may be performed on any fabric205including, alternatively and without restriction, fabric160produced using the cold-spinning process100, fabric produced using conventional spinning and/or weaving processes and/or on fabric produced by weaving, at conventional temperatures, yarn145produced using the cold spinning process100.

The cold-finishing process200may be, without restriction, performed in the same facility as the spinning process100and or weaving step150, performed in a different facility, or may be performed on stored fabric or purchased fabric at a specialized fabric-finishing facility. The ambient temperature of the fabric finishing facility is not restricted.

The cold finishing process200includes, preferably, a cold bleaching step210, cold mercerizing step220, cold dyeing step230. The cold finishing process200also includes washing steps240and260following the cold bleaching step210and the cold dyeing step230, respectively. The entire finishing process as depicted inFIG. 3may include steps in addition to the cold finishing process200. It is preferred that the cold bleaching step210, cold mercerizing step220, and cold dyeing step230all be performed, but the instant invention also includes embodiments of the cold finishing process200wherein one of said steps is omitted and embodiments wherein two of said steps are omitted.

The preferred embodiment of the cold finishing process200also includes a greige batching step310and singeing step320. The greige batching step310and the singeing step320may be omitted, but if included are performed first. If the greige batching step310and singeing step320are performed, they are performed as is well-known and standard in the textile arts. If they are not performed, the cold bleaching step210is performed first. If the greige batching step310is performed and the singeing step320is performed, the cold bleaching step210is performed thereafter.

The cold bleaching step210is performed by immersing the fabric205, through padding, in a bleaching liquor and rotating it in said bleaching liquor for 8-10 hours, said bleaching liquor being maintained at approximately 35 C-40 C. The constituents of the bleaching liquor are given in TABLE 2 with the acceptable concentration range for each and the concentration for use in the preferred embodiment of the cold bleaching step210of the instant invention. For each constituent of the bleaching liquor, the preferred compound or chemical for use as that constituent is listed in parentheses, but any chemical or compound known in the art to be suitable for use with cotton fibers and fulfills that function may be used, without restriction. The formulation herein may be adjusted to produce desired whiteness levels, desizing as measured by the TEGEWA scale, and/or capillary properties as desired for the finished product or as required for later steps in the instant cold finishing process100.

The cold bleaching step210as described herein replaces the need for separate scouring and desizing steps as required in conventional fabric finishing. This reduces the complexity of the instant cold finishing process200and reduces time required to perform the instant cold finishing process200.

Following the cold bleaching step210, the preferred embodiment of the invention includes a first washing step240and width setting step250. The first washing step240is necessary to the invention, but the width setting step250may be omitted. The first washing step is performed by washing the bleached fabric205in washing solution, preferably but without restriction water, maintained at 85-95 C, preferably at 90 C. The width setting step250, if performed, is performed as is well-known and standard in the art.

After the first washing step240and, if included, the width setting step250, the preferred embodiment of the invention includes a cold mercerizing step220. The cold mercerizing step220is performed by immersing the fabric205in a caustic soda solution of 26 to 32 degrees Baume (hereinafter, “Be”), maintained at 15 to 18 C. The caustic soda (Sodium Hydroxide/NaOH and referred to herein as “caustic soda”) solution is preferably 30 Be. Fabric containing cotton fibers and mercerized as described herein as the cold mercerizing step260has superior characteristics to fabric containing cotton fibers mercerized in the standard process, which is performed at temperatures of 60 C-90 C.

Following the cold mercerizing step220, the preferred embodiment includes a cold dyeing step230. Proceeding to the cold dyeing step230without including an additional width setting step, as is required in the conventional and well-known fabric finishing processes, increases efficiency of the fabric finishing process. The cold dyeing step230is performed by immersing at least a portion of the fabric205, through padding, in dye liquor maintained at 20 C-25 C. Preferably, all of a given piece of fabric205is immersed. The dye liquor in the preferred embodiment of the cold dyeing step230includes a dye having at least one vinyl sulphone reactive group, but other dyes appropriate for fabrics including cotton fibers may be used. Example dyestuffs commonly available and known in the art that are suitable for use in the cold dyeing step230include, without restriction, Bezaktiv (V/S range) Jakazol (VS/HLF/CE/DS/VS/ME range), and Everzol (ED/LX/LF range). The fabric205is held in the dye liquor for approximately 16 hours, and is rotated during the period it is held in the dye liquor.

After the cold dyeing step230, the fabric205is subjected to a second washing step260to remove excess dye liquor. The second washing step260is performed using water at 85-95 C, and preferably at 90 C. The fabric205may be optionally treated with additional finishing steps330such as, without restriction, Sanforizing, Calendering, and/or other fabric finishing processes. These additional finishing steps330may be performed, without restriction, at ambient temperatures or at the temperatures well-known in the art for the performance of such steps.

When the full preferred embodiment of the cold finishing process200of the instant invention is used, that is, the fabric205is finished using the cold bleaching step210, the cold mercerizing step220, and the cold dyeing230step, the characteristics of the finished fabric are improved as compared to fabric finished using an industry-standard fabric finishing process. TABLE 3, below, gives the specifications of cotton fabric finished using the preferred embodiment of the cold finishing process200of the instant invention.

Fabric finished using the cold finishing process200may be used for any purpose fabric containing cotton fibers is used for in industry, fashion, and/or any other field.