EP3956503A2 - Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn - Google Patents
Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarnInfo
- Publication number
- EP3956503A2 EP3956503A2 EP20722463.5A EP20722463A EP3956503A2 EP 3956503 A2 EP3956503 A2 EP 3956503A2 EP 20722463 A EP20722463 A EP 20722463A EP 3956503 A2 EP3956503 A2 EP 3956503A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- core
- sheath
- fibrous core
- composite yarn
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01H—SPINNING OR TWISTING
- D01H1/00—Spinning or twisting machines in which the product is wound-up continuously
- D01H1/02—Spinning or twisting machines in which the product is wound-up continuously ring type
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01H—SPINNING OR TWISTING
- D01H4/00—Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques
- D01H4/04—Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques imparting twist by contact of fibres with a running surface
- D01H4/08—Rotor spinning, i.e. the running surface being provided by a rotor
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/04—Blended or other yarns or threads containing components made from different materials
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/32—Elastic yarns or threads ; Production of plied or cored yarns, one of which is elastic
- D02G3/328—Elastic yarns or threads ; Production of plied or cored yarns, one of which is elastic containing elastane
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/36—Cored or coated yarns or threads
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
- D03D15/217—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based natural from plants, e.g. cotton
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
- D03D15/225—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based artificial, e.g. viscose
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
- D03D15/47—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads multicomponent, e.g. blended yarns or threads
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
- D03D15/56—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads elastic
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
- D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/01—Natural vegetable fibres
- D10B2201/02—Cotton
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/20—Cellulose-derived artificial fibres
- D10B2201/22—Cellulose-derived artificial fibres made from cellulose solutions
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2211/00—Protein-based fibres, e.g. animal fibres
- D10B2211/01—Natural animal fibres, e.g. keratin fibres
- D10B2211/02—Wool
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
Definitions
- Fibers in the meaning of the present invention shall incorporate staple fibers having a definite length and filaments having an indefinite length.
- fibers in the form of staple fibers they can for example be provided from natural sources, such as cotton or wool.
- Fibers in the form of filaments, such as nylon filaments or polyester filaments can for example be produced by melt spinning.
- the part of providing suitable fibers for spinning the fibers to a yarn requires energy, natural resources and causes costs. In order to reduce costs, energy and/or natural resources for providing the fibers, it is desirable to use recycled fibers for the yarn production.
- the axial strength of the sheath material is at least 25%, 50%, 75%, 100%, 125% or 150% greater than the sheath material strength.
- the axial strength of the core material is between 2 cN/tex and 12 cN/tex, in particular between 4 cN/tex and 10 cN/tex, more particular between 6 cN/tex and 8 cN/tex.
- the axial strength of the sheath material is between 8 cN/tex and 20 cN/tex, in particular between 10 cN/tex and 18 cN/tex, more particular between 12 cN/tex and 16 cN/tex.
- the axial strength of the composite yarn is between 6 cN/tex and 20 cN/tex, in particular between 9 cN/tex and 17 cN/tex, more particular between 11 cN/tex and 15 cN/tex.
- the axial strength being indicated in cN/tex preferably relates to the breaking tenacity.
- the difference in axial strength being indicated in % preferably relates to the comparison of the breaking tenacity of the core material and of the sheath material.
- the differences in the axial strength can be even greater.
- a sheath material having a yarn count of 10 Ne corresponds to a yarn count of 60 tex wherein a yarn count of the core material of 30 Ne corresponds to a yarn count of about 20 tex.
- a sheath material having a breaking tenacity of 6 cN/tex and a yarn count of 30 Ne particularly has a breaking strength of 120 cN.
- a sheath material having a breaking tenacity of 12 cN/tex and a yarn count of 10 Ne would have a breaking strength of 720 cN.
- the sheath material would have a breaking tenacity being 100 % greater than the breaking tenacity of the core material.
- the total breaking strength of the sheath material would be 500 % greater than the total breaking strength of the core material. The skilled person will know how to calculate the differences regarding the total axial strength on the basis of the later described preferred yarn counts of the sheath material and the core material.
- the inventor of the present invention has surprisingly found that surrounding the fibrous core with a sheath, which sheath material has a greater axial strength than the core material, increases the overall axial strength of the composite yarn. It has surprisingly been found that with the inventive concept, even composite yarns comprising a high content of recycled fibers, such as up to 20%, 25%, 30% or 35% of recycled fibers, can be produced having still enough overall axial strength to be manufactured to fabrics, such as woven fabrics. It has been found that the axial strength of the sheath material can be increased by decreasing the content of short fibers, in particular recycled fibers, in the sheath material and/or by increasing the average fiber length of the sheath material.
- Cellulosic fibers are in particular fibers made with ethers or esters of cellulose, which can be obtained from the bark, wood or leaves of plants, or from other plant-based material.
- the fibers may particularly comprise hemicellulose and lignin.
- the used cellulosic fibers can particularly be natural cellulosic fibers or manufactured cellulosic fibers.
- natural cellulosic fibers in the form of cotton fibers, silk fibers and/or linen fibers can be used.
- Manufactured cellulose fibers are particularly fibers being produced by processing plants into a pulp and then extruding the pulp in the same ways as synthetic fibers, such as polyester or nylon.
- manufactured cellulose fibers can be used in the form of rayon fibers and/or viscose fibers.
- the composite yarn can be processed with pretreatment processes, such as dyeing, prior to weaving the yarns.
- the composite yarn is processed to yarns that are raw, sulphur, dyed, reactive dyed, indigo (ring) dyed, pigment dyed, direct dyed, indanthrene dyed, acid dyed, natural dyed, etc.
- the core material can be colored or raw.
- the sheath material can be dyed, in particular indigo dyed, before the sheath material is surrounded around the fibrous core.
- a composite yarn in particular for weaving comprising at least one fibrous core made of a core material comprising recycled fibers, in particular recycled cellulosic fibers and/or recycled synthetic fibers, and a sheath surrounding the at least one fibrous core, the sheath being made of a sheath material, in particular a sheath material comprising cellulosic fibers and/or synthetic fibers, having a lower content of recycled fibers than the core material.
- a lower content of recycled fibers can in particular also include the absence of recycled fibers at all in the sheath material.
- sheath material comprising recycled fibers can increase the axial strength of the composite yarn, if the content of recycled fibers in the sheath material is lower than the content of recycled fibers in the core material.
- the content of the recycled fibers in the core material and in the sheath material is preferably measured in weight percentage.
- the content of the recycled fibers in the core material and in the sheath material can particularly be measured by weighing the amount of recycled fibers being intended for the core material for a specific length, for instance 1000 m, of a composite yarn and weighing the amount of recycled fibers being intended for the sheath material or the same length of the composite yarn.
- fresh fibers such as staple fibers being longer than recycled fibers or filaments, can be introduced into the core material or the sheath material.
- the core material consists to at least 30%, 50%, 70%, 90%, 95% or 100% of recycled fibers, preferably of recycled fibers having a fiber length of maximally 25 mm, 20 mm, 15 mm or 10 mm.
- the sheath material consists to less than 30%, 20%, 10%, 5 % or 2% of recycled fibers, in particular is free of recycled fibers, preferably of recycled fibers having a fiber length of maximally 25 mm, 20 mm, 15 mm or 10 mm.
- a composite yarn in particular for weaving comprising at least one fibrous core made of a core material comprising recycled fibers, in particular recycled cellulosic fibers and/or recycled synthetic fibers, and a sheath surrounding the at least one fibrous core, the sheath being made of a sheath material, in particular a sheath material comprising cellulosic fibers and/or synthetic fibers, having a greater average fiber length than the core material.
- a composite yarn in particular for weaving comprising at least one fibrous core made of a core material comprising recycled fibers, in particular recycled cellulosic fibers and/or recycled synthetic fibers, the core being produced by open-end spinning and a sheath being made of a sheath material, in particular a sheath material comprising cellulosic fibers and/or synthetic fibers, the sheath being surrounded around the at least one fibrous core by spinning, in particular by ring spinning. It has surprisingly been found that by producing the at least one fibrous core by open-end spinning, the strength of the fibrous core can significantly be increased compared to other spinning technologies.
- a fibrous core by open-end spinning from a core material comprising or consisting of fibers having a fiber length of less than 26 mm, 24 mm or 22 mm, and/or of at least 10 mm, 15 m or 20 mm, leads to a fibrous core having a greater axial strength than when using fibers having a greater fiber length, such as a fiber length being greater than 26 mm, 28 mm, 30 mm, 32 mm, 34 mm or 36.
- Particularly good results could be achieved by using a core material according to the first, the second and/or the third aspect of the present invention, in particular of their preferred embodiments, for the open-end spinning.
- the fibrous core in order to spin the sheath around the at least one fibrous core, the fibrous core needs a minimum axial strength because the fibrous core is usually tensioned during the spinning of the sheath around the core. If the axial strength of the at least one fibrous core is not high enough, the fibrous core particularly breaks upon trying to spin the sheath around the fibrous core due to the tension stress. In this regard, it has surprisingly been found that upon using the open-end spinning technology, even a fibrous core consisting of up to 100% of recycled fibers and/or having an average fiber length between 10 mm and 15 mm can be produced with a sufficient axial strength for being processed to a composite yarn in the subsequent spinning action.
- the axial strength of the at least one fibrous core achieved by the open-end spinning technology might not be sufficient for processing the fibrous core in weaving manufacturing steps, such as the weaving itself and pre-treatment steps, such as dyeing of yarns.
- the fibrous core is surrounded by the sheath to provide a composite yarn having enough axial strength to be processed for the manufacturing of fabrics, such as woven fabrics.
- the sheath material particularly has a greater axial strength than the core material such that the axial strength of the composite yarn is increased by surrounding the fibrous core by the sheath.
- the axial strength of the composite yarn can substantially be provided by the sheath surrounding the core.
- the sheath serves for two purposes. The first is to increase the axial strength of the composite yarn such that the composite yarn can be processed in fabric manufacturing processes, such as in dyeing processes and in weaving processes. The second is particularly to surround the fibrous core in such a way, that even in case the core breaks upon the processing of the composite yarn, the fibers of the core remain in the composite yarn.
- the term surrounding shall be understood as enclosing or encapsulating the fibrous core in circumferential direction to the length of the fibrous core.
- the sheath holds the fibrous core, in particular compresses the core, to prevent the core from breaking and/or from being separated from the composite yarn upon processing the composite yarn.
- the fibrous core particularly only needs to provide enough axial strength so as not to break during the process step of surrounding the core with the sheath material, in particular during spinning, more particularly, during ring spinning.
- the axial strength of the composite yarn can substantially be provided by the sheath material.
- substantially in this regard it is meant that most of the axial strength of the composite yarn, in particular at least 70%, 90%, 95% or even 100% is provided by the composite yarn.
- the at least one fibrous core can even weaken the composite yarn due to its relatively low axial strength, which weakening can be compensated by the sheath surrounding the core.
- fibers of a low fiber length such as the previously described fiber lengths for the core material, for the open-end spinning of the fibrous core
- fibers having a greater average fiber length such as the previously described fiber lengths for the sheath material, or filaments for spinning the sheath around the fibrous core, in particular by ring spinning.
- Ring spinning and open-end spinning is described in more detail below in relation to the method according to the eight and seventh aspect of the present invention and in relation to the arrangement according to the eigth aspect of the present invention. It shall be clear that the inventive composite yarn according to the first, the second, the third and/or the fourth aspect of the invention can be produced and structured according to the method according to the eight and seventh aspect of the present invention and/or according to the arrangement according to the eigth aspect of the present invention.
- the at least one fibrous core has a yarn count of 40 ⁇ 20 Ne, preferably of 30 ⁇ 10 Ne, more preferably of 30 ⁇ 5 Ne, most preferably of 30 ⁇ 3 Ne or of 30 ⁇ 1 Ne.
- the sheath has a yarn count of 20 ⁇ 15 Ne, preferably of 15 ⁇ 10 Ne, more preferably of 15 ⁇ 5 Ne, most preferably of 15 ⁇ 3 Ne or of 15 ⁇ 1 Ne.
- the composite yarn has a yarn count of 15 ⁇ 14 Ne, preferably of io ⁇ 9 Ne, more preferably of 10 ⁇ 5 Ne, most preferably of 10 ⁇ 3 Ne or of 10 ⁇ 1 Ne .
- the mass per length of the sheath material can particularly be increased, thereby increasing the axial strength of the sheath material, particularly without affecting the desired yarn count of the composite yarn.
- the composite yarn consists to at least 20%, preferably at least 30%, more preferably at least 35%, of the core material. Additionally, or alternatively, the composite yarn consists to maximally 80%, preferably maximally 70%, more preferably maximally 65% of the sheath material. It has surprisingly been found that with the present invention, composite yarns having up to 35% of the core material can be produced which still has enough axial strength to be processed to fabrics, particularly by weaving. Since due to the present invention even fibrous cores consisting to 100% of recycled fibers can be produced and surrounded by a sheath, composite yarns can be provided having up to 35% of recycled fibers.
- even composite yarns can be provided having 35% of recycled fibers having an average fiber length of less than a length between 10 mm and 15 mm or of an average fiber length within a range of 10 mm to 15 mm or within a range of 20 mm to 25 mm, wherein the composite yarn particularly has still enough axial strength to be processed to a fabric, in particular by weaving.
- the sheath material consists to at least 50%, 70%, 90%, 95% or 100% of staple fibers and/or of filaments.
- the sheath material can be a combination of staple fibers and filaments.
- the sheath material can comprise to 95 % of staple fibers and to 5 % of filaments, such that the filaments particularly increase the axial strength of the core material.
- the staple fibers of the sheath material preferably have a greater average fiber length than the recycled fibers as particularly stated abore and below.
- the sub-sheath can for example be surrounded around the fibrous core prior to surrounding the fibrous core by the sheath material such that the sub sheath is particularly encompassed by the at least one fibrous core and the sheath.
- This can for instance be of advantage when a fibrous core has a relatively low axial strength being not sufficient for surrounding a sheath material having relatively high linear density, such as a yarn count of 15 Ne, around the fibrous core.
- the fibrous core can previously be surrounded by a sub-sheath material having lower linear density, such as a yarn count of 30 Ne, to increase the axial strength of the fibrous core by the sub-sheath material.
- the fibrous core with the increased axial strength can particularly be surrounded with a sheath material having a greater linear density, such as yarn count of 15 Ne.
- the sub-sheath being encompassed by the at least one fibrous core and the sheath can mean that the sub sheath is bordered on its inner side in radial direction of the core axis by the at least one fibrous core and on its outer side in radial direction of the core axis by the sheath.
- the composite yarn comprises at least two, three, four or five of the at least one fibrous core made of a core material comprising recycled fibers, wherein preferably the core material of each fibrous core consists to at least 30%, 50%, 70%, 90%, 95% or 100% of recycled fibers, preferably of recycled fibers having a fiber length of maximally 25 mm, 20 mm, 15 mm or 10 mm.
- each of the fibrous cores comprise substantially to the same content of recycled fibers.
- the term substantially the same content shall particularly contain deviations of up to ⁇ 10 %, 5% or 3%.
- the fibrous cores can also have different contents of recycled fibers.
- the fibrous cores can have a substantially the same or a different yarn count.
- one, more or all of the fibrous cores can be produced and/or structured according to the previously and subsequently described at least one fibrous core.
- the fibrous cores can particularly be aligned substantially parallel to each other or twisted around each other.
- one or more of the fibrous cores can be surrounded by a sub-sheath prior to aligning or twisting the fibrous cores to each other.
- the sub-sheath can, particularly after aligning or twisting the cores around each other, form the sheath around the fibrous cores.
- the fibrous cores are preferably further surrounded by a sheath.
- the composite yarn further comprises at least one, in particular at least two, three, four or five, additional core.
- the at least one additional core is particular at least one additional filament core, such as at least one elastic filament core and/or at least one inelastic filament core.
- the at least one additional core is particular at least one additional fibrous core being made of an additional core material, wherein the additional core material comprises a lower content of recycled fibers than the core material, comprises a lower average fiber length than the core material and/or consists to at least 50%, 70%, 90%, 95 %, or 100% of staple fibers having a greater fiber length than the recycled fibers or of filaments.
- a filament core within the meaning of the present invention is a core consisting of one filament.
- a filament within the meaning of the present invention is particularly a single fiber of indefinite length, for instance produced by melt spinning.
- An additional core material can particularly comprise staple fibers and/or filaments.
- Additional cores comprising filaments can particularly comprise a plurality of filaments, such as at least one, two, three or four filaments being aligned with each other, in particular substantially parallel, or twisted around each other. In particular some of the filaments being comprised in the additional core material can be aligned with each other while others of the filaments being comprised in the additional core material can be twisted around the aligned filaments.
- An elastic filament within the meaning of the present invention shall be particularly be capable of stretching at least about two times of its initial length, i.e. package length. After having stressed an elastic filament by stretching at least about two times of its initial length, an elastic recovery of at least 90 % up to 100 % arises.
- the elastic recovery is a parameter for the elastic filament.
- the elastic recovery in percent represents a ratio of the length of the elastic filament following the release of tension stress with respect to the length of the elastic filament prior to be subjected to said tension stress (package length).
- An elastic recoveiy having a high percentage, i.e. between 90 % and 100 %, is to be considered as providing an elastic capability of returning substantially to the initial length after the stress was applied.
- an inelastic filament is defined by a low percentage elastic recovery, i.e. the inelastic filament will not be able to return substantially to its initial length, if a stretching of at least two times of its initial length is realized.
- Said percent elastic recovery of filaments can be tested and measured according to the standard ASTMD3107, the entire content of which is expressively incorporated hereinto by reference.
- Said test method ASTMD3107 is a testing method for a fabric made from yarns. Of course, it is possible to deviate from the test results of the fabric the elastic recovery for the yarn itself.
- a yarn testing method and testing device can be used for individual measuring filaments and/or yarns. For instance the previously mentioned USTER TENSOR RAPID-3 device (Uster, Switzerland) can be used for measuring percentage of elastic recovery of filaments and/or yarns.
- an elastic filament are a polyurethanic fiber such as elastane, spandex and those filaments that have similar elastic properties.
- an elastic filament within the meaning of the invention particularly may be stretched at least 300 % or 400 % of the package length (e.g. as elongation at break).
- Package length shall be understood as the initial or original length of the elastic filament while essentially no tensile tension is applied.
- Examples of elastic filaments within the meaning of the invention include but are not limited to, Dowxla, Dorlastan (Bayer, Germany), Lycra (Invista, USA), Clerrspan (Globe Mfg. Co., USA), Glospan (Globe Mfg.
- the at least one filament core in the inventive composite yarn particularly serves to increase the axial strength of the composite yarn.
- the at least one filament core can be an elastic filament core.
- the use of an additional elastic filament core can particularly serve to increase the elastic behavior of the composite yarn.
- the at least one additional filament core can be an inelastic filament core.
- the use of an inelastic filament core particularly serves to restrict the elongation of the composite yarn in axial direction in reaction to a force being applied in axial direction to the composite yarn.
- the at least one additional filament core in particular in the form of an inelastic filament core or an elastic filament core, can be aligned, in particular substantially parallel, to the at least one fibrous core and/or twisted around the at least one fibrous core. Additionally or alternatively, at least two filament cores, for instance two elastic filament cores, can be twisted around each other and be aligned in their twisted form substantially parallel to the at least one fibrous core. Additionally, or alternatively, two elastic filament cores can be twisted around one inelastic filament core and be aligned in their twisted form to the at least one fibrous core.
- the inventive composite yarn is a core spun yarn, in particular a core spun yarn with at least one fibrous core and a sheath comprising staple fibers and optionally filaments.
- the sheath of the core spun yarn can particularly be a fibrous sheath which can incorporate staple fibers and filaments or a staple fiber sheath consisting to too % of staple fibers.
- a fibrous core in particular to be surrounded by a sheath to provide a composite yarn is provided.
- the fibrous core is spun of at least 5 %, in particular 10 %, short fibers with a fiber length of maximally 25 mm and of at least 10 %, in particular 20% or 30 %, long fibers with a fiber length of more than 25 mm.
- a composite yarn in particular for weaving is provided, comprising at least one fibrous core according to the fifth aspect of the invention, and a sheath surrounding the at least one fibrous core.
- the inventive fibrous core according to the fifth aspect of the invention can be described in the embodiment of the composite yarn.
- the fifth aspect of the invention relates to a fibrous core which does not necessarily need to be combined with a sheath.
- the previously and subsequently described embodiments shall encompass the fibrous core as such and additionally or alternatively the composite yarn with the fibrous core and the sheath.
- the fifth aspect of the present invention can be combined with one or more of the first, second, third, fourth, sixth and seventh aspect of the present invention and vice versa.
- the fibrous core and/or the sheath can be made as described in combination with one or more of the first, second, third, fourth, sixth and seventh aspect of the present invention.
- the fibrous core and/or the sheath can be made as described within one or more of the previously and subsequently described preferred embodiments.
- the fibrous core and/or the sheath does not necessarily need to be made according to the particularly essential features of the first, second, third/fourth, sixth and seventh aspect of the invention. Rather, the fibrous core and/or the sheath can be made according to the individual features described within the respective embodiments.
- a short fiber within the meaning of the fifth and eight aspect of the present invention is in particular a fiber having a fiber length of maximally 25 mm.
- short fibers can be fibers having a fiber length of maximally 24 mm, 23 mm, 22 mm or 20 mm and/or of at least 2 mm, 4 mm, 6 mm, 8 mm, 10 mm, 12 mm or 15 mm, in particular an average length between 20 mm and 25 mm.
- a short fiber might also be longer than 25, in particular up to maximally 32 mm or 28 mm.
- the short fibers can in particular be the previously described recycled fibers. However, short fibers can also be fresh fibers.
- a long fiber within the meaning of the fifth and eight aspect of the present invention is in particular a fiber having a fiber length of more than 25 mm, in particular of at least 26 mm, 27 mm, 28 mm, 29 mm, 30 mm, 31 mm or 32 mm.
- a problem normally arising when using short fibers for the yarn production is that the resulting yarn has a low axial strength due to the short fiber length of the short fibers. Therefore, such yarns can normally not be used for fabrics, in particular not for clothes such as jeans fabric, denim or dungarees.
- the inventors of the present invention have found that the previously and subsequently described combination of short fibers with long fibers in particular within the meaning of the fifth, sixth, eight and/or ninth aspect of the invention enables to use composite yarns with cores comprising contents of short fibers of more than 5%, in particular 10%, in denim manufacturing.
- a core being spun of at least or maximally a certain percentage of fibers, in particular of short fibers, long fibers, post-consumer-fabric-fibers and/or man-made fibers, shall in particular be understood in that the core consists to at least this percentage value of the respective fibers. However, this does not necessarily mean that the core cannot have additional components compared to these fibers. For instance, a core being spun of at least 5 % short fibers and at least 10 % long fibers could comprise 85 % percent other fibers such as the subsequently described third group of fibers. However, such a core could also only consist of the short fibers and the long fibers.
- the content of fibers having a specific length can in particular be measured by one or more of the following methods.
- a sample of a specific length such as a length of 10 cm, 30 cm, 50 cm, 100 cm, 200 cm or 500 cm, can be cut of a fibrous core or a composite yarn.
- the fibers of this sample can be separated from each other. Subsequently the length of each fiber can be measured, for instance by means of a microscope. Subsequently, the number of fibers with a specific length within the sample can be counted.
- samples of different cores or yarns with the same sample length can be compared with regard to the content of fibers having a specific length. For instance all fibers having a length between 20 mm and 25 mm could count. Subsequently the overall number of fibers within the samples could be count. In particular, a minimum length such as 10 mm, 8 mm, 6 mm, 4 mm, 2 mm or 1 mm could be defined for fibers to be count so that very short fibers being hard to identify and count could be excluded from the measurement. Subsequently, the number of fibers with a length between 20 mm and 25 mm could be divided through the overall number of fibers being in particular longer than the minimum length.
- the content of fibers in a fibrous core or in a composite yarn of a specific length can refer to the quotient of fibers with such a length or length ratio and the overall number of fibers, in particular the overall number of fibers being longer than 10 mm, 8 mm, 6 mm, 4 mm, 2 mm or 1 mm.
- the weight of the fibers could be used to compare the percentage value. With the above method, this could be achieved by considering, the length, thickness and/or density of the fibers within the calculation. Additionally or alternatively, the fibers of a specific length or a length ratio could be separated from the remaining fibers. Subsequently the weight of the fibers with the specific length or length ratio could be divided through the overall weight of the sample.
- At least 30 96, 50 96, 70 96, 90 % or 95 % of the short fibers have a fiber length between 10 mm and 25 mm, more preferably between 15 mm and 25 mm, most preferably between 20 mm and 25 mm.
- At least 30 96, 50 96, 70 96, 90 96 or 95 96 of the long fibers have a fiber length between 25 mm and 50 mm, preferably between 28 mm and 42 mm, more preferably between 32 mm and 38 mm.
- a fibrous core in particular to be surrounded by a sheath to provide a composite yarn is provided.
- the fibrous core is spun of at least 5 96 short fibers and of at least 10 96 long fibers, wherein the long fibers are at least 2 mm longer than the short fibers.
- a composite yarn in particular for weaving is provided, comprising at least one fibrous core according to the sixth aspect of the invention, and a sheath surrounding the at least one fibrous core.
- the inventive fibrous core according to the sixth aspect of the invention can be described in the embodiment of the composite yarn.
- the sixth aspect of the invention relates to a fibrous core which does not necessarily need to be combined with a sheath.
- the previously and subsequently described embodiments shall encompass the fibrous core as such and additionally or alternatively the composite yarn with the fibrous core and the sheath.
- the sixth aspect of the present invention can be combined with one or more of the first, second, third, fourth, fifth and seventh aspect of the present invention and vice versa.
- the fibrous core and/or the sheath can be made as described in combination with one or more of the first, second, third, fourth, fifth and seventh aspect of the present invention.
- the fibrous core and/or the sheath can be made as described within one or more of the previously and subsequently described preferred embodiments.
- the fibrous core and/or the sheath does not necessarily need to be made according to the particularly essential features of the first, second, third, fourth, fifth and seventh aspect of the invention. Rather, the fibrous core and/or the sheath can be made according to the individual features described within the respective embodiments.
- the fibrous core can be made of a core material, in particular of the previously and subsequently described core material.
- the core material can, as described for the at least one fibrous core of the sixth aspect of the invention, be spun of at least 5 % short fibers and of at least 10 % long fibers, wherein the long fibers are at least 2 mm longer than the short fibers.
- the sheath can be made of a sheath material, in particular of the previously and subsequently described sheath material.
- At least 30 %, 50 %, 70 %, 90 % or 95 % of the long fibers are at least 3 mm, 5 mm, 7 mm, 10 mm, 15 mm, 20 mm, 30 mm or 40 mm longer than the short fibers. Additionally or alternatively, at least 30 %, 50 %, 70 %, 90 % or 95 % of the long fibers are between 2 mm and 40 mm, preferably between 3 mm and 30 mm, more preferably between 5 mm and 20 mm, most preferably between 7 mm or 10 mm and 15 mm, longer than the short fibers.
- the short fibers are recycled fibers, in particular post-consumer-fabric-fibers. Additionally or alternatively, the short fibers consist of fibers of the same material or of different materials, such as natural fibers, in particular cotton fibers and/or wool fibers, and/or man-made fibers, in particular synthetic fibers and/or regenerated natural fibers.
- the long fibers are man-made fibers, such as synthetic fibers and/or regenerated natural fibers. Additionally or alternatively, the long fibers are recycled fibers.
- the fibrous core is spun of at least 10%, 15 %, 20 %, 25 % 30 %, 40 % or 50 % of the short fibers. Additionally or alternatively, the fibrous core is spun of at least 15%, 20 %, 25 %, 30 %, 35 %, 40 % or 50 % of the long fibers.
- the fibrous core in the fibrous core is spun of at least 60 % of the short fibers. Additionally or alternatively, the fibrous core is spun of at least 10 %, 15 %, 20 %, 25 %, 30 %, 35 % or 40 % of the long fibers. Alternatively, the fibrous core is spun of at least 65 %, 67 % or 70 % of the short fibers. Additionally or alternatively, the fibrous core is spun of at least 10 %, 15%, 20 %, 25 % or 30 % of the long fibers.
- the fibrous core consists of the short fibers, the long fibers and a third group of fibers, wherein the fibrous core is spun of maximally 85 %, 70 %, 50 %, 30 %, 20 %, 15 %, 10 %, 5 %, 3 96 or 1 % of the third group of fibers.
- a fibrous core according to this embodiment does only consist of the long fibers, the short fibers and the group of third fibers.
- the third group of fibers can in particular be fibers being different to the short fibers and/or long fibers according to one or more of the embodiments of these fibers.
- the third group of fibers can be fibers with a length between 1 mm and 9 mm and with a length of more than 50 mm.
- the short fibers are for instance specified as cotton fibers while the long fibers are specified to be polyester fibers, the third group of fibers could encompass any kind of fibers of other materials.
- the fibrous core can be made of a core material, in particular of the previously and subsequently described core material.
- the core material can, as described for the at least one fibrous core of the seventh aspect of the invention, be spun of at least 5 % post-consumer-fabric-fibers and of at least 10 % man-made-fibers.
- the sheath can be made of a sheath material, in particular of the previously and subsequently described sheath material.
- man-made fibers in particular for the long fiber is of particular advantage. It seems that the strength and the tenacity of man-made fibers in particular in combination with the fiber length of the long fibers increases the axial strength of the at least one fibrous core. It has surprisingly been found that the use of man-made fibers in particular for the long fibers increases the strength of the fibrous core in that a composite yarn with a fibrous core comprising at least 20 %, 30 %, 40 %, 50 %, 60 % or 70 % of post-consumer-wear fibers and/or short fibers can be used for manufacturing denim fabrics.
- the short fibers are recycled fibers.
- the short recycled fibers can be obtained from post-consumer-fabrics or from post-consumer-non- textile products. However, preferably, the recycled short fibers are obtained from post consumer-fabrics, such as woven fabrics or knitted fabrics.
- the use of recycled fibers is in general of particular advantage because it increases the sustainability of the resulting composite yarn by decreasing the amount of fresh fiber consumption.
- the recycled short fibers can be of any material which can be converted into fibers from post-consumer products.
- the post-consumer-fabric product can be of any material which can be separated form post-consumer fabrics in the form of fibers.
- the fibrous core is spun of at least 60 % of the post-consume-fabric-fibers. Additionally or alternatively the fibrous core is spun of at least 10 %, 15 %, 20 %, 25 %, 30 %, 35 % or 40 % of the man-made-fibers. Alternatively the fibrous core is spun of at least 65 %, 67 % or 70 % of the post-consumer-fabric-fibers. Additionally or alternatively, the fibrous core is spun of at least 10 %, 15%, 20 %, 25 % or 30 % of the man-made-fibers.
- the fibrous core has a yarn count between 10 Ne and 40 Ne, preferably between 15 Ne and 35 Ne, more preferably between 20 Ne and 30 Ne, most preferably between 23 Ne and 26 Ne.
- the fibrous core is made by open-end spinning or by ring-spinning.
- the sheath is spun of at least 50 %, in particular of at least 60 %, 70 %, 90 % or 95 %, of long fibers in particular with a fiber length of more than 25 mm or with a fiber length being 2 mm longer than the length of short fibers or of post-consumer fabric fibers in the core, wherein preferably at least 30 %, 50 %, 70 %, 90 % or 95 % of the long fibers in the sheath have a fiber length between 25 mm and 50 mm, preferably between 26 mm and 42 mm, more preferably between 27 mm and 38 mm.
- the composite yarn is made to at least 5 %, 10 %, 15 % or 20 % and/or to maximally 45 %, 40 % or 35 % of the at least one fibrous core. Additionally or alternatively, the composite yarn is made to at least 55 %, 60 %, 65 % and/or to maximally 95 %, 90 %, 85 %, 80 % of the sheath. Additionally or alternatively, the composite yarn has a yarn count between 3 Ne and 40 Ne, preferably between 8 Ne and 30 Ne, more preferably between 10 Ne and 18 Ne.
- the content of short fibers in the core can be increased up to 20 %, 30 %, 40%, 50%, 60 % or even up to 70 % while the resulting composite yarn can in particular still be used for denim manufacturing.
- a ring spun yarn was for instance spun in clockwise direction around the yarn axis
- the twist can be removed by twisting the yarn in reverse clockwise direction around the yarn axis.
- This is also known in the art as opening of a ring spun yarn.
- the fibers After opening the ring spun yarn, the fibers extend again substantially parallel to the yarn axis.
- open-end spun yarns cannot be opened by this method because the fibers are entangled to strong with each other. Therefore, a person skilled in the art can immediately recognize whether a yarn was spun by open-end spinning or by ring spinning.
- the twist of a ring spun yarn can be quantified by twist measuring or testing machines, such as by the Uster Zweigle Twist Tester 5.
- a method for producing a composite yarn in particular for weaving comprising the steps of providing recycled fibers, in particular recycled cellulosic fibers and/or recycled synthetic fibers, open-end spinning the recycled fibers into at least one fibrous core, providing sheath fibers, in particular cellulosic sheath fibers and/or synthetic sheath fibers, and spinning, in particular ring spinning, the sheath fibers around the at least one fibrous core to produce a sheath surrounding the core.
- inventive method enables the production of an inventive composite yarn. It shall be clear that the inventive method can be conducted such that the inventive composite yarn as described above and below can be produced.
- a fibrous core within the meaning of the present invention may particularly be defined as a continuous collection of fibers held together by twisting the fibers around each other.
- the twist can in general be produced by different spinning technologies, such as ring spinning and open-end spinning. Ring spinning and open-end spinning as well as differences and advantages of the respective spinning technology are described below.
- a method for spinning a fibrous core, in particular a fibrous core according to one or more of the fifth to the seventh aspect of the invention, in particular to be surrounded by a sheath to provide a composite yarn, in particular a composite yarn according to one or more of the first to the fourth aspect of the invention, is provided.
- the method comprises the steps of providing short fibers with a fiber length of maximally 25 mm, providing long fibers with a fiber length of more than 25 mm, mixing the short fibers and the long fibers, and spinning the mixed short fibers and long fibers into a fibrous core having at 5 %, in particular at least 10 %, short fibers and at least 10 %, in particular at least 20 % or 30 %, long fibers.
- the method comprises the step of detecting too short fibers in the short fibers, such as fibers being smaller than 20 mm, 15 mm, 10 mm or 5 mm, detecting too short fibers in the long fibers, such as fibers being smaller than 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, 27 mm, 26 mm or 25 mm, and/or detecting to long fibers in the long fibers, such as fibers being longer than 50 mm, 42 mm or 38 mm, and/or the step of cleaning the short fibers and/or the long fibers by removing the dust, such as too short or too long fibers, dirt and/or other foreign materials, from the fibers, and/or the step of washing the short fibers and/or the long fibers, and/or the step of drying the short fibers and/or the long fibers, wherein preferably one or more of these steps are conducted in a blow room
- the step of spinning comprises drafting the mixed short fibers and long fibers, in particular a tuft formed from the mixed short fibers and long fibers, in particular by means of at least one carding frame, in particular wherein the drafted short fibers and long fibers are spun into the fibrous core by means of at least one, preferably at least two, fly frames.
- a method for spinning a fibrous core, in particular a fibrous core according to one or more of the fifth to the seventh aspect of the invention, in particular to be surrounded by a sheath to provide a composite yarn, in particular a composite yarn according to one or more of the first to the fourth aspect of the invention comprises the steps of providing post-consumer-fabric fibers, providing man-made fibers, mixing the post-consumer-fabric-fibers and the man- made fibers, and spinning the mixed post-consumer-fabric-fibers and man-made fibers into a fibrous core having at least 5 % post-consumer-fabric-fibers and at least 10 % man-made fibers.
- the step of mixing is conducted in a mixing station, such as a multi-mixer, in a blow room, in particular wherein mixing comprises feeding in particular by means of a take-up roller the post-consumer- fabric-fibers and the man-made fibers from separate fiber supplies onto a conveying means, in particular a conveyer belt, in particular wherein the post-consumer-fabric-fibers and man made fibers are conveyed to a carding station to form the mixed post-consumer-fabric-fibers and man-made fibers to a tuft to be processed to the fibrous core in the subsequent spinning step.
- a mixing station such as a multi-mixer
- the method comprises the step of detecting too short fibers in the post-consumer-fabric-fibers, such as fibers being smaller than 20 mm, 15 mm, 10 mm or 5 mm, detecting too short fibers in the man-made fibers, such as fibers being smaller than 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, 27 mm, 26 mm or 25 mm, and/or detecting to long fibers in the man-made fibers, such as fibers being longer than 50 mm, 42 mm or 38 mm, and/or the step of cleaning the post-consumer-fabric- fibers and/or man-made fibers by removing the dust, such as too short or too long fibers, dirt and/or other foreign materials, from the fibers, and/or the step of washing the post- consumer-fabric-fibers and/or the man-made fibers, and/or the step of drying the post- consumer-fabric-fibers and/or
- the step of spinning comprises drafting the mixed post-consumer-fabric-fibers and man-made fibers, in particular a tuft formed from the mixed post-consumer-fabric-fibers and man-made fibers, in particular by means of at least one carding frame, in particular wherein the drafted post- consumer-fabric-fibers and man-made fibers are spun into the fibrous core by means of at least one, preferably at least two, fly frames.
- the step of spinning the mixed post-consumer-fabric-fibers and man-made fibers into the fibrous core (3) is conducted by open-end spinning.
- the step of providing the post-consumer-fabric-fibers comprises separating fibers from a fabric in particular by combing the fibers out of a fabric in particular by means of an opening roller and/or wherein providing man-made fibers comprises spinning a viscous solution into the man-made fibers; in particular by urging a viscous solution through a spinneret
- the invention also relates to a method for producing a composite yarn, in particular a composite yarn according to one or more of the first to the fourth aspect of the invention, in particular for weaving.
- the method comprises the steps of spinning at least one fibrous core according to one or more of the eight to the eleventh aspect of the invention and spinning a sheath around the at least one fibrous core.
- the step of spinning the sheath around the at least one fibrous core is conducted by ring spinning.
- the method according to the ninth, tenth and/or eleventh aspect of the invention aspect of the invention can enable the production of an inventive composite yarn and/or fibrous core.
- the inventive method can be conducted such that the inventive composite yarn as described above and below can be produced.
- the methods according to the ninth, tenth and/or eleventh aspect of the present invention can be combined with each.
- the fibrous core and/or the sheath can be made as described with one or more of the first to the seventh aspect of the present invention.
- the fibrous core and/or the sheath can be made as described within one or more of the previously and subsequently described preferred embodiments.
- the fibrous core and/or the sheath does not necessarily need to be made according to the essential features of the first to the seventh aspect of the invention. Rather, the fibrous core and/or the sheath can be made according to the individual features described within the respective embodiments.
- the fibrous core can be made of a core material, in particular of the previously and subsequently described core material.
- the core material can, as described for the at least one fibrous core, be made to at least 10 % of short fibers with a fiber length of maximally 25 mm and to at least 30 % of long fibers with a fiber length of more than 25 mm.
- the sheath can be made of a sheath material, in particular of the previously and subsequently described sheath material.
- merging the short fibers and the long fibers into a core material can be conducted in a blow room, also known as blend room.
- merging the short fibers and the long fibers into a core material can comprise the step of opening compressed bales of short fibers and compressed bales of long fibers.
- the step of merging can comprise detecting too short fibers in the short fibers, such as fibers being smaller than 20 mm, 15 mm, 10 mm or 5 mm, detecting too short fibers in the long fibers, such as fibers being smaller than 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, 27 mm, 26 mm or 25 mm, and/or detecting to long fibers in the long fibers, such as fibers being longer than 50 mm, 42 mm or 38 mm. Additionally subsequently or alternatively, the step of merging can comprise cleaning the short fibers and the long fibers by removing the dust, such as too short or too long fibers, dirt and/or other foreign materials, from the fibers. Additionally subsequently or alternatively, the step of merging can comprise mixing and blending of the long fibers and the short fibers into the core material.
- the method can comprise the step of carding the core material.
- Carding is in particular a mechanical process that disentangles, cleans and intermixes the core material into a continuous web or sliver suitable for subsequent processing. This can in particular be achieved by passing the core material between differentially moving surfaces covered with card clothing. It can in particular break up locks and unorganised clumps of fibers and then align the individual fibers to be parallel with each other.
- the short fibers and the long fibers can be processed by a draw frame, preferably by two draw frames.
- the short fibers and the long fibers can subsequently to the draw frame and previously to the spinning action by processed by a Fly frame.
- the short fibers and the long fibers can be processed by a comber machine prior to processing them with the draw frame.
- an arrangement for producing a composite yarn in particular for weaving comprising an open-end spinning arrangement for spinning recycled fibers, in particular recycled cellulosic fibers and/or recycled synthetic fibers, into a core yarn, and a further spinning arrangement, in particular a ring spinning arrangement, for spinning a sheath, in particular a sheath being made of a sheath material comprising cellulosic fibers and/or synthetic fibers, around the core yarn.
- the inventive arrangement can be designed such that one or both of the inventive methods in particular for producing the inventive composite yarn can be conducted. Further, one or both of the inventive methods can be defined such that it can be conducted with the inventive arrangement.
- a ring spinning arrangement particularly comprises a fiber supply, such as a sheath material supply or a core material supply, a drafting system, a ring, and a driven spindle to wind the spun yarn around the spindle, in particular to form a yarn package.
- the fiber supply can be in the form of a roving being wound around a fiber supply spindle.
- the roving is unwound from the fiber supply spindle and drafted by the drafting system. Thereby, the weight per length of the roving is particularly reduced, such that the yarn count in Ne is increased.
- Ring spun yarns and open-end spun yarns can particularly be destinguished from each other by one or more of the following differences.
- the fibers in a ring spun yarn are more parallel to each other than the fibers in an open-end spun yarn.
- a ring spun yarn has a compact structure, with essentially no wrapper fibers or hooked fibers.
- the intensive fiber migration which in turn is influenced by the triangular geometry of the spinning zone of an ring spinning arrangement, and in particular the high spinning tensions lead to a self-locked structure of ring-spun yarns resulting to a relativ high axial strength of ring-spun yarns, in particular to a higher axial strength than that of open- end spun yarns.
- the fiber supply particularly comprises a feed roller for feeding the open-end spinning arrangement with a sliver, the sliver comprising recycled fibers.
- the fiber supply further comprises a feed plate, in particular a spring loaded feed plate, confining a passage for the sliver from the fiber supply to the drafting system.
- the feed plate urges the sliver against the feed roller.
- a sliver shall particularly be understood as a sliver of an already used textile, also known as post-consumer textile.
- the feed roller particularly urges a fiber beard of the sliver to project into the drafting system.
- the sliver is particularly urged from a can beneath the open-end spinning arrangement via a feed trumpet to the feed roller.
- the feed roller particularly grips the sliver and urges it into the region of the opening roller.
- a spring is provided urging the feed plate towards the feed roller and thereby particularly the sliver to towards the feed roller.
- the fiber supply is particularly stopped either by stopping the feed roller rotation or by pivoting the trumpet, such that the feeding of the sliver is particularly automatically stopped. Therefore, a yarn- sensing arm can be provided.
- the drafting system particularly comprises a mechanical drafting system and a pneumatic drafting system.
- the pneumatic drafting system is particularly arranged downstream the mechanical drafting system.
- the mechanical drafting system comprises an opening roller for opening the sliver.
- the opening roller particularly comprises a cylindrical body on the circumferential of which needles or saw-like teeth are provided for combing fibers out of the sliver, which is also known as opening.
- the opening roller combs through the fiber beard projecting into the drafting system and thereby pulls fibers out of the sliver.
- rear such as powder and fibers being shorter than 10 mm, 8 mm, 6 mm, 4 mm or 2 mm are also opened from the opening roller and can be spun into the open end spun yarn which can cause defects in the open-end spun yarn.
- slivers having a high level of cleanliness in particular a maximum amount of waste of less than 10 %, 5 %, 3 %, 1 %, preferably of less than 0,5 % or of less than 0,1 %.
- a waste output can be provided to separate the waste from the fibers to be used for the open-end spun yarn in the twisting system.
- successive layers of fibers are laid into the inside surface of the rotor, which is also known as“doubling” or“back doubling” as explained below.
- Such doubling particularly decreases, in particular evens out, minor irregularities in the yarn.
- doubling contributes to the low irregularity and greater uniformity of open-end spun yarn.
- the opening roller can particularly be driven by 5.000 to 10.000 rotations per minute.
- the rotor can particularly be driven by 50.000 to 200.000 rotations per minute or by about 100.000 rotations per minute.
- the delivery speed, namely the speed with which the open-end spun yarn is drawn out of the rotor can particularly be set to 50 to 500 m/min, 100 to 400 m/min or to 150 to 250 m/min.
- the number of twists per meter in an open-end spun yarn can particularly be set to 150 to 300 twists per meter, in particular to 200 to 250 twists per meter.
- the Draft of the open-end spun yarn can particularly be adjusted between 25 and 400.
- the rotor diameter can particularly be chosen between 32 to 65 mm.
- one difference between open-end spun yarns and ring spun yarns is a tighter fiber control due to a higher spinning tension.
- less fiber migration occurs in rotor spinning, resulting in a more uniform fiber orientation in the yarn structure which produces smoother, more uniform yarns, however having a lower relative axial strength, in particular a lower breaking tenacity.
- the impact of fiber friction in the rotor groove particularly results in some fibers that are only partially twisted, which particularly contributes to a lower yarn strength compared to ring spun yarns.
- the number of fibers can particularly be reduced from 20.000 in the cross section of sliver to 5 to 10 in the cross section of the output of the transport tube. This represents a draft of 4.000 to 5000.
- the fibers In order to produce an open-end spun yarn having about 100 yarns, the fibers have to be laid in successive layers in the rotor (back doubling). Thereby, the overall draft can be increased compared to the draft from the sliver to the output of the transport tube.
- the overall draft shall be particularly understood as the ratio between the number of fibers in the sliver and the number of yarns in the resulting open-end spun yarn.
- an open-end spun yarn having 100 fibers in its cross section, being produced from a sliver having 20.000 fibers in its cross section has a draft of 200.
- the twisting system of the open end spinning arrangement particularly comprises a rotor.
- the fibers are particularly mechanically twisted to a continuous yarn.
- the torque causing the respective twist insertion is particularly applied by the rotation of the rotor with respect to the point of the yarn tail contacting the rotor navel.
- the amount of twist (turns per meter) is determined by the ratio between the rotor speed (rpm) and the take up speed (meter/ min).
- Fig. 9 a schematic side view of a composite yarn comprising a fibrous core and two filament cores
- Fig. 16 a schematic view of a ring spinning arrangement for manufacturing a composite yarn as shown in Fig. 1 and 2 and in Fig. 3 and 4;
- cross-sections 13’, 13” as well as the number of fibers 7’, 7” in the Figures 3 to 14 shall only illustrate how to differentiate between the cross section 13” of the sheath and the cross section 13’ of the fibrous core 3 and the fibers 7’, 7” comprised therein.
- neither preferred numbers of the fibers 7’, 7” comprised within the cross sections 13’, 13” nor relations between the number of fibers 7’, 7” in the cross-sections 13’, 13” can be derived from these illustrations.
- the fibrous cores and/or at least one fibrous core and the at least one filament core 21 can be aligned substantially parallel to each other. Thereby, the fibrous cores 3 can contact each other as illustrated in Figure 6 and 7 or being spaced from each other within the composite yarn 1. Further, the fibrous cores 3 can be twisted around each other.
- the waste output 57 can particularly lead the waste 59 to a collecting chamber (not shown) from which it can be removed.
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Abstract
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Application Number | Priority Date | Filing Date | Title |
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EP19000188.3A EP3725923A1 (en) | 2019-04-16 | 2019-04-16 | Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn |
PCT/EP2020/000086 WO2020211977A2 (en) | 2019-04-16 | 2020-04-16 | Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn |
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EP3956503A2 true EP3956503A2 (en) | 2022-02-23 |
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EP19000188.3A Pending EP3725923A1 (en) | 2019-04-16 | 2019-04-16 | Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn |
EP20722463.5A Pending EP3956503A2 (en) | 2019-04-16 | 2020-04-16 | Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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EP19000188.3A Pending EP3725923A1 (en) | 2019-04-16 | 2019-04-16 | Composite yarn, fabric comprising the composite yarn, method for producing a composite yarn and arrangement for producing a composite yarn |
Country Status (6)
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US (1) | US20220195639A1 (en) |
EP (2) | EP3725923A1 (en) |
JP (1) | JP2022530362A (en) |
CN (1) | CN113994037B (en) |
BR (1) | BR112021020759A2 (en) |
WO (1) | WO2020211977A2 (en) |
Families Citing this family (9)
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US11359309B2 (en) | 2018-12-21 | 2022-06-14 | Target Brands, Inc. | Ring spun yarn and method |
WO2020152717A1 (en) * | 2019-01-27 | 2020-07-30 | Sharadha Terry Products Ltd | System for manufacturing textile products from roving waste material and method thereof |
EP4013909A4 (en) * | 2019-08-13 | 2024-01-24 | Allbirds, Inc. | Composite yarns |
US20210324548A1 (en) * | 2020-04-17 | 2021-10-21 | Universal Fibers, Inc. | Sharp color effect yarn |
EP4056743A1 (en) | 2021-03-10 | 2022-09-14 | Calik Denim Tekstil San. Ve Tic. A.S. | Woven fabric, garment and method for manufacturing the woven fabric |
CN113832582A (en) * | 2021-08-26 | 2021-12-24 | 江阴市茂达棉纺厂有限公司 | Composite yarn and preparation and coloring method thereof |
EP4212657A1 (en) * | 2022-01-14 | 2023-07-19 | Calik Denim Tekstil San. Ve Tic. A.S. | Textile substrate with enhanced biodegradability |
CN115449957B (en) * | 2022-10-01 | 2024-05-28 | 佛山市顺德区丽轩纺织实业有限公司 | Household textile fabric and preparation method thereof |
CN116163042A (en) * | 2023-03-23 | 2023-05-26 | 江苏海特服饰股份有限公司 | Preparation process and device of renewable fiber color spinning spray yarn |
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-
2019
- 2019-04-16 EP EP19000188.3A patent/EP3725923A1/en active Pending
-
2020
- 2020-04-16 EP EP20722463.5A patent/EP3956503A2/en active Pending
- 2020-04-16 WO PCT/EP2020/000086 patent/WO2020211977A2/en unknown
- 2020-04-16 JP JP2021561858A patent/JP2022530362A/en active Pending
- 2020-04-16 BR BR112021020759A patent/BR112021020759A2/en unknown
- 2020-04-16 CN CN202080043781.6A patent/CN113994037B/en active Active
- 2020-04-16 US US17/604,141 patent/US20220195639A1/en active Pending
Also Published As
Publication number | Publication date |
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JP2022530362A (en) | 2022-06-29 |
US20220195639A1 (en) | 2022-06-23 |
CN113994037B (en) | 2024-03-26 |
BR112021020759A2 (en) | 2021-12-14 |
CN113994037A (en) | 2022-01-28 |
EP3725923A1 (en) | 2020-10-21 |
WO2020211977A2 (en) | 2020-10-22 |
WO2020211977A3 (en) | 2020-11-26 |
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