Abstract:
This invention discloses a method for manufacturing ultra-thin fiber yarn having elastic characteristics. Ultra-thin fiber Textured Yarn and thermoplastic fiber are concurrently fed into a compression air jet system to produce elastic ultra-thin fibers. The two materials are made into a novel yarn with elastic function using the process of this invention, which is simpler as compared with other traditional processes associated with manufacturing elastic complex yarn. The process of this invention is capable of manufacturing elastic complex yarns with excellent size stability, capable of being easily woven, suitable for the textile and slopwork industries, and capable of producing textiles with good elasticity and high degree of comfort.

Description:
[0001]    This invention relates to a novel ultra-thin fiber Textured Yarn with elastic characteristics and its manufacturing method. Specifically, this invention relates to a novel elastic ultra-thin fiber Textured Yarn manufactured by concurrently feeding spun ultra-thin fiber Textured Yarn and spun thermoplastic fiber into a compression air jet system and passing the resulting product through wire feed and winding rollers.  
           [0002]    Republic of China&#39;s Patent No. 127812 entitled “the manufacturing method of iso-shrinkage ultra-thin fiber Textured Yarn” teaches a traditional method for manufacturing ultra-thin fiber. Ultra-thin fiber Textured Yarn with boiling water shrinkage below 10% and high shrinkage low crimpled gray yarn with boiling water shrinkage above 15% are compounded and processed to form a single yarn unit. Fabrics manufactured using yarns made with such a traditional method have thick feel and noticeable stiffness, which are appreciated by visual examination of the draped fabrics. However, these fabrics lack elasticity and are not comfortable when worn.  
           [0003]    In response to thick feel, stiffness and lack of comfort associated with fabrics produced using traditional methods such as the method discussed above, and in order to produce yarn with elastic covering characteristics, manufacturers often wrap the produced yarn around a Spandex (trade name for a type of polyurethane elasticity silk) periphery to form a single/dual wrapped yarn. Additionally, the produced yarn is knobbed with high speed air and wrapped around the periphery of a LYCRA Spandex to produce elastic covering yarn. Although such Spandex-based yarns have elasticity, production of the latter involve complex manufacturing procedures and high manufacturing cost. The following shortcomings are clear noticeable:  
           [0004]    1. Higher manufacturing cost due to technical complexity associated with raw materials.  
           [0005]    2. Higher manufacturing cost due to technical complexity associated with the manufacturing process.  
           [0006]    3. Process not applicable to high temperature dyeing and finishing; and easy coloring embrittlement results due to moist heat intolerance.  
           [0007]    4. Alkali (NaOH) intolerant decrement processing.  
           [0008]    5. Uneasy tension control exist during the opening of band yarn and during finish processing, which is caused by unwanted elasticity and reduced product quality; and industrial processing efficiency is negatively influenced due to extreme process difficulties.  
           [0009]    It is an object of this invention to solve the shortcomings associated with Spandex-based yarns production and other traditional methods of producing yarns with elastic covering characteristics.  
           [0010]    Another object of this invention is to produce high-class yarn with elastic function by false twisting thermoplastic fiber with self-winding elasticity characteristics into ultra-thin fiber via a compression air jet system.  
           [0011]    Still another object of this invention is to simplify the process of manufacturing elastic complex yarns and to reduce the cost associated with producing elastic complex yarns. Still further, another object of this invention is to manufacture elastic complex yarns with excellent size stability, capable of being easily woven, suitable for the textile and slopwork industries, and capable of producing textiles with good elasticity and high degree of comfort.  
         SUMMARY OF THE INVENTION  
         [0012]    This invention discloses a method for manufacturing novel ultra-thin fiber Textured Yarn with elastic characteristics. The process involves blending ultra-thin fiber Textured Yarn with thermoplastic fiber having self-winding characteristics.  
           [0013]    The ultra-thin fiber Textured Yarn of this invention is manufactured by heating, false twisting and spinning of continuous long fiber using traditional or compound spinning methods. The thermoplastic plastic of this invention is manufactured by spinning two thermoplastic polymers with different shrinkage. The ultra fiber Textured Yarn and the thermoplastic fiber are concurrently fed into a compression air jet and compounded into the elastic ultra-thin fiber yarn of this invention. Finally, the produced elastic ultra-thin fiber processing yarn is fed through wire feed rollers and subsequently wrapped with winding rollers. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    [0014]FIG. 1: Shows a compound false-twist processing flow sheet for manufacturing elastic ultra-thin fiber processing yarn. The equipment symbols associated with the flow sheet are as follows: ( 1 ) Silk guide; ( 2 ) First wire; ( 3 ) Heater; ( 4 ) Cooling plate; ( 5 ) Friction ingot group; ( 6 ) Silk guide; ( 7 ) Second wire feed roller; ( 8 ) Compression air jet system; ( 9 ) Third wire feed roller; ( 10 ) Elastic ultra-thin fiber processing yarn; and ( 11 ) Batch roller.  
         [0015]    [0015]FIG. 2: Shows a self-winding elastic thermoplastic fiber used for manufacturing the elastic ultra-thin fiber yarn of this invention. The figure shows the configuration of two thermoplastic polymers of different shrinkages into a fiber cross section constituting both polymers. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]    This invention discloses novel Ultra-thin Fiber Textured Yarn with elastic characteristics and its manufacturing method. Specifically, this invention relates to novel elastic ultra-thin fiber Textured Yarn manufactured by concurrently feeding spun ultra-thin fiber Textured Yarn and spun thermoplastic fiber into a compression air jet system and passing the resulting product through wire feed and winding rollers.  
         [0017]    The ultra-thin fiber Textured Yarn of this invention is obtained by heating, false twisting, and post processing of continuous long fiber woven with general-synthetic fiber by using traditional spinning or compound spinning methods to produce a yarn whose filament size is below 0.5 denier. The traditional spinning method, which usually occurs after a false twisting process, uses a single polymer under traditional conditions and with traditional equipment to spin out continuous long fiber yarn whose filament size is below 0.5 denier. The continuous long fiber yarn is subsequently false twisted and processed into Ultra-thin fiber Textured Yarn whose filament size is below 0.5 denier. In contrast, the compound spinning method, which usually occurs after a false twisting process, uses two different polymers under traditional conditions and with traditional equipment to spin out continuous long fiber yarn whose filament size is below 0.5 denier. The continuous long fiber yarn is subsequently false twisted and processed into Ultra-thin fiber Textured Yarn whose filament size is below 0.5 denier.  
         [0018]    The second material used to manufacture the invention of this patent application is thermoplastic fiber with self-winding elastic characteristics. The thermoplastic fiber is obtained by configuring two thermoplastic polymers of different shrinkages into a fiber cross section by spinning with a compound spinneret having the desired proportionality. The different contraction stresses between the interfaces of the two thermoplastic polymers with different shrinkages form spring-like screw and generate self-winding elasticity. See the manufacturing diagram shown in FIG. 2.  
         [0019]    To form the ultra-thin fiber Textured Yarn with elastic characteristics of this invention, thermoplastic fiber with self-winding elastic characteristics and continuous long fiber are first individually spun using traditional spinning methods or compound spinning methods. Specifically, the continuous fiber is false twisted, spun, heated, subsequently false twisted and post processed into a ultra-thin fiber Textured Yarn whose filament size is below 0.5 denier. The ultra-thin fiber Textured Yarn produced from the continuous long fiber and the thermoplastic fiber is compounded to form an in-process Textured Yarn. The in-process Yarn is passed through a weaving process, a dyeing process and a finishing process. The high in-process temperature is utilized to generate shrinkage difference within the thermoplastic fiber thereby inducing elastic characteristics in the final product.  
         [0020]    The manufacturing process steps of this invention are summarize as follows: ultra-thin fiber Textured Yarn is manufactured by heating, false twisting and spinning of continuous long fiber using traditional or compound spinning methods; separately, thermoplastic fiber with self-winding characteristics is manufactured by spinning two thermoplastic polymers with different shrinkage after first being melted and spun using a compound spinneret of desired proportion; the ultra fiber Textured Yarn and the thermoplastic fiber are concurrently fed into a compression air jet are compounded into elastic ultra-thin fiber processing yarn; and the resulting elastic ultra-thin fiber processing yarn is passed through wire feed rollers and wrapped with winding rollers.  
         [0021]    Referring to FIG. 1 for additional clarification of the manufacturing process steps of this invention, ultra-thin fiber spinning cake (A) is relaxed via silk guide ( 1 ), and passed through a first wire feed roller ( 2 ). The resulting ultra-thin fiber product is heated with a heater ( 3 ), passed over a cooling plate ( 4 ) and through a friction ingot group ( 5 ). The ultra-thin fiber product is then passed through a second wire feed roller ( 7 ) to form the Textured Yarn. Steps  1 - 7  are the heating, extending, curl reshaping and cooling processes required to produce the ultra-thin Textured Yarn material of this invention.  
         [0022]    Still referring to FIG. 1 of the inventive process, at the moment the ultra Textured Yarn is fed through the second wire rollers ( 7 ), self-winding thermoplastic fiber (B) is incorporated into the ultra Textured Yarn through the silk guide ( 6 ), and combined with the Textured Yarn and fed into a compression air jet system ( 8 ) with air nozzle supplied with a considerable amount of pressure. The ultra-thin Textured Yarn and the thermoplastic fiber are compounded into an elastic ultra-thin fiber processing yarn ( 10 ) and guided by a third wire feed roller ( 9 ) down stream. Finally, the elastic yarn with feed rate controlled by the third feed roller ( 9 ) and the winding roller ( 11 ) is produced.  
         [0023]    Still referring to FIG. 1 of this invention, the friction ingot group ( 5 ) is not restricted to any one type or any one combination. All well-known ingot groups such as friction disc, friction belt, and pin ingot, etc. are applicable. The air nozzle of the compression air jet system ( 8 ) is not restricted to any one type or any one combination. All well-known nozzles, such as ordinary nozzle and mixed fiber nozzle etc. are applicable. To achieve the maximum integration of the thermoplastic fiber into the ultra-thin Textured Yarn to form a compound (elastic ultra-thin fiber) with good reliability, the number of processed yarn shall be over 85 sections/m.  
         [0024]    The elastic ultra-thin fiber processing yarn ( 10 ) of this invention can be woven into cloths and textiles of various shapes. Due to the elastic effect demonstrated prior to hot water treatment no problem of pull control exists; therefore, various shapes can be obtained through knitter, shuttle and shuttle less loom. The weaving and quality characteristics of this invention are superior to contemporaneous elastic yarn complexes. By manufacturing the elastic yarn with thermoplastic polymers interface having two different shrinkage, which forms spring-like screw due to the difference in shrinkage stress when exposed to high temperature during post processing, textiles produced using this invention demonstrated excellent elasticity and a high degree of comfort.  
         [0025]    By way of examples of exploitation/comparison and explanation, the evaluation method, the manufacturing processes, conditions and process components, though not limited to the exploitations, of the present invention may be as follows:  
         [0026]    Explanation of Elasticity Evaluation Method  
         [0027]    Workbench: INSTRON—6021 universal tensile testing machine  
         [0028]    Method:  
         [0029]    a. Tailor 2.5 cm×30 cm test piece under the condition of room temperature without tension (Containing clamping section 10 cm).  
         [0030]    b. Test rate for 1.667 mm/Sec Return speed for 10.0 mm/Sec  
         [0031]    c. Test piece pre-load 12 g  
         [0032]    d. Fixed pull of 1000 g  
         Calculation: elastic extension (fixed pull 1000 g)=( A 2 −A 1)÷ A 1×100%  
         [0033]    A1: Test piece length before stretching  
         [0034]    A2: Test piece length applying fixed pull 1000 g  
         [0035]    (Example of Exploitation)  
         [0036]    360d/48f polyester, an upgraded polyester compound, ultra-thin fiber spinning cake (A) is relaxed via silk guide ( 1 ), and passed through a first wire feed roller ( 2 ) The ultra-thin fiber product is heated to 160° C. with a heater ( 3 ) (having a temperature range between 100-200° C.). The resulting product is passed over a cooling plate ( 4 ), false twisted by passage through a friction ingot group ( 5 ) and extended to 2.28 times with the second wire feed roller ( 7 ) (having an extension multiple of between 1.3-4.0), to form the Textured Yarn. At the moment the ultra-thin Textured Yarn is fed through the second wire roller ( 7 ), 75d/24f spun polyester, self-winding elastic fiber (B) is incorporated into the second wire feed roller ( 7 ) via silk guide ( 6 ) at speed of 500 m/minute (the second wire feed roller speed range is between 300-900 m/minute). The resulting product is combined with the Textured Yarn and fed into the air jet compression system ( 8 ) with air nozzle having air pressure of about 50 kg/m 2 , at the guiding end of the yarn. The ultra-thin Textured Yarn and the thermoplastic fiber are compounded into an elastic ultra-thin fiber processing yarn ( 10 ) and guided by a third wire feed roller ( 9 ) down stream.  
         [0037]    A 225d/72d elastic ultra-thin elastic yarn with feed rate controlled by the third feed roller ( 9 ) and the winding roller ( 11 ) is produced consistent with the process flow chart shown in FIG. 1. The processed yarn is used as filling, wrapped with 75d/36f Textured Yarn, weaved and reduced by 25%. Post processing such as burring, dyeing to produce cloth of enhanced thickness, drape, wax, particularity, peach skin feeling and elastic extension (fixed pull 1000 g) that reaches 23.1% were performed. Clothing produced using this exploitation maintained a high degree of comfort when worn.  
       EXAMPLE OF COMPARISON  
       [0038]    In this example, conditions are similar to the processing conditions above. However, the self-winding elastic thermoplastic fiber (B) is replaced with 45% high shrinkage low crimpled gray yarn having boiling water shrinkage and dimensions of 75d/36f to produce 225d/84f iso-shrinkage ultra-thin fiber Textured Yarn. Similar to the above exploitation, the processed yarn is used as filling, wrapped, weaved and reduced. Post processing such as burring, dyeing to produce cloth of enhanced thickness, drape, wax, particularity, peach skin feeling and elastic extension (fixed pull 1000 g) that reaches only 5.8% were performed. Thus, clothing produced using this example possessed many shortcomings and lack the needed comfort when worn.  
         [0039]    Comparing the example of exploitation with the example of comparison, it is clear that the use of properly processed thermoplastic fiber with self-winding elastic performance and ultra-thin fiber Textured Yarn resulted in the production of unique elastic ultra-thin fiber with enhanced intrinsic performance, as compared with traditional ultra-thin fiber Textured Yarn.