WO2009090501A1

WO2009090501A1 - Method for producing ring dyeable core-spun yarn

Info

Publication number: WO2009090501A1
Application number: PCT/IB2008/050148
Authority: WO
Inventors: Guven Dokumaci
Original assignee: Dekor Tekstil Sanayi Ve Ticaret Anonim Sirketi
Priority date: 2008-01-16
Filing date: 2008-01-16
Publication date: 2009-07-23

Abstract

The present invention is a method for producing a core-sheath yarn which can provide a visual effect on the textile product upon wearing out of the dye on the yarn in garments and textile products, by providing that only the sheath (2) is dyed leaving the core (4) in the center undyed during yarn dyeing, or that the core and the sheath are dyed or that both the core and the sheath are produced without dyeing.

Description

METHOD FOR PRODUCING RING DYEABLE CORE-SPUN YARN

Technical Field

The present invention relates to having only the walls of the yarn dyed and leaving the core in the center undyed during yarn dyeing process in textile especially in the production of denim. Thus, it is enabled to provide an effect on the garments and products as a result of the wearing out of the dye on the yarn.

Background Art

Having been initially produced in France, production and use of denim fabrics in USA has become widespread in the 18^th century [1] and even though nowadays they are produced in modern plants not much difference could be created in the form of dyeing thereof. In the state of the art, usually, warp yarns are dyed for loom beams by means of the method of immersion - oxidization in the machinery called "Slasher". The main producers of dyeing machinery of this system in the world are "Benniger", "Master", "Ramallumin", "Sucker-Muller" and "Westpoint".

In this system, there are drawbacks such as the requirement that the length of the product should be long, and the high rates of waste at the breakdown of the machinery. The distance traveled by the yarn within the machine is approximately 1.500 meters. This gives a hint about the said wastes.

Another method in denim dyeing is rope dyeing. The first producer of the related machine is "Morrison" company. The substance of the method is that it provides dyeing of the ropes formed by gathering 336 to 448 threads, by means of the method of immersion - oxidization again in a continuous system. Cost of a breakdown or an error is very high in both Slasher (warp dyeing) and Rope (rope dyeing) methods, because of the use of continuous systems and the requirement of working with lengthy materials.

A third system or method of dyeing is the Loop dyeing (Looptex) system. Although it is an alternative to "Slasher" machine for companies which do not have enough space, the method is again a warp dyeing method and the same drawbacks related to the other two methods still exist in this method.

Additionally, in the application there are also techniques of dyeing yarns in hanks. This method is an old method, which has technically fallen behind compared to the recent systems, which is too difficult to be repeated for indigo dyes and which does not any longer enable dyeing in the quality sought by the textile industry.

In any case, these methods require either labor intense working or working with lengthy materials, or problems of repeatability and waste arise.

Furthermore thickness of the yarns dyed in the said systems cannot be thinner than Neβ30 (British cotton yarn numbering system). It is possible in "Rope" system to wind the dyed yarn onto a bobbin but it requires a high cost. Additionally, decreasing of the yarn numbers (thinning) does not allow working with the yarn.

Nowadays the concept of fashion has changed and the alternatives offered to the end user within a season have increased; in other words, the shop windows are now dressed more than four times in a year. Additionally, the variety of the products offered has also increased accordingly. All of these require short length and flexible production in fabrics. Since small amounts of production can also be realized with the present yarn production method, it is possible to obtain short lengths. Different fashion concepts and technical textile fabrics can be attained by various fiber alternatives, i.e. natural, artificial and synthetic fibers or mixtures thereof.

On the other hand, since we can apply the same production conditions to knitted torsion yarns, alternatives will also be increased in knitted fabrics in addition to the woven fabrics.

Departing from the requirement that the warp colors in normal denim fabrics are to be indigo in the same color, and diversifying with yarns dyed by indigo wearable dyestuffs of different tones and even in different colors in the warp, will enable production of many new fashioned fabrics. On the other hand, by using these kinds of yarns, diversity of the fabrics will be enhanced with the jacquard weaving and knitting looms.

Moreover, one of the leading problems of our time is "Global Warming". This problem has also changed dressing characteristics of people and has directed individuals to select lighter cloths [2]. Being able to be applied especially to yarns thinner than Neβ30, as opposed to the classical methods mentioned above, the present method will satisfy the need of the fashion industry.

In dyeing our new yarn, whose core is naturally hydrophobic or provided with hydrophobic characteristic, and whose outer part is comprised of hydrophilic fibers, with the impregnation or exhaust method, less chemicals and dyestuffs will be used, being kinder to the environment, since only the outer layer will be processed.

The Turkish utility model No. TR 200000373, within the state of the art, discloses conversion of an indigo dyed yarn into a bobbin in the "rope dyeing" system. Brief Description of the Invention

The object of the present invention is to realize a method for producing ring dyeable core-spun yarn, which method will enable production of different textile fabrics with diverse fiber alternatives, in other words natural, artificial and synthetic fibers or mixtures thereof.

Another object of this invention is to realize a method for producing core-spun yarn dyed or dyeable in the form of a ring, by which method indigo dyeing can be performed, and knitted torsion yarn can be produced.

A further object of the invention is to realize a method for producing core-spun yarn dyed or dyeable in the form of a ring, which method enables obtaining lighter textile products by producing yarns thinner than Neβ30.

An additional object of the invention is to realize a method for producing core- spun yarn dyed or dyeable in the form of a ring, by which method less water and dye is used and less waste materials are generated by way of enabling dyeing of only the outer part of the yarn without dyeing the core constituting the inner part of the yarn.

Detailed Description of the Invention

The method realized to fulfill the objects of the present invention and the machine, on which the method is applied, are illustrated in the accompanying figures, in which;

Figure 1 is the flow chart of the method for producing ring dyeable core-spun yarn. Figure 2 is the schematic view of the machine on which the method for producing ring dyed or dyeable core-spun yarn is applied. Figure 3 is the cross sectional view of the core-spun yarn.

The parts in the figures are individually numbered, where the numbers refer to the following:

1. Method for producing ring dyeable core-spun yarn

2. Staple fiber roving

3. Apron

4. Yarn core 5. Drawing roller

6. Spindle

7. Core-spun yarn

8. Core-spun yarn apparatus

9. Cop

The ring dyeable core-spun yarn is produced upon following the below given stages.

10. The staple fiber roving (2) is passed between the aprons (3). 20. The yarn core (4) is drawn by the drawing rollers (5).

30. The staple fiber roving (2) is jacketed onto the yarn core (4).

40. The jacketed core-spun yarn (7) is twisted.

50. The core-spun yarn (7) is wound onto the spindle (6).

The roving, in other words the staple fiber roving (2) which has arrived at the ring spinner at the spinning mill is wound to the drawing rollers (5) after they are drawn by the aprons (3) which ensure that it is wound without disintegrating. In the drawing roller (5), the staple fiber roving (2) and the yarn core (4) which is a staple or filament yarn coming from the core-spun yarn apparatus (8) combine and begin to be jacketed. Jacketing is completed by the twisting procedure between the drawing roller (5) and the spindle (6), and the product is wound onto the cop (9) and thus core-spun yarn (7) is obtained.

The said invention is based on the principle of twisting and winding of fiber, which is dyed with wearable dyestuff or provided with different characteristics or possess different characteristics, onto a previously spun or filament yarn of diverse characteristics (natural, finished, dyed, etc.), by means of a core-spun yarn apparatus (8) in a ring yarn machine and thereby forming an upper layer called jacket in the form of a ring.

This way, if we take the fiber diversity of these yarns into consideration, the yarns to be formed will not only serve fashion but also various sectors as technical textile.

In the system, the fiber, which is dyed or natural or on which a special chemical substance is applied, should be advanced until the roving procedure in a normal carded or combed ring yarn factory. In other words, it must be processed in the mixing willow, card, drawing and roving machines for carded line, and in the mixing willow, card, drawing 1, wadding, comber, drawing 2 and roving machines for combed yarn line.

If different materials are used for yarn to be used as the core, some adjustments suitable to the characteristics of the material used may be required.

Adaptation of core-spun yarn production method (1) to a ring yarn factory is quite simple. The existing yarn plants will be able to be used by disposing a core-spun yarn apparatus (8) for each spindle.

The yarn to be obtained and the products to be produced therefrom can be conveniently used in the technology of our time. Furthermore, by diversifying the woven and knitted fabrics to be produced by using these yarns with respect to color, design and performance, a commercial activity will be provided to the textile industry.

Core-spun yarn (7) is obtained by combining staple fiber roving (2) and yarn core (4). As the core-spun yarn (4) is comprised of two different layers, many different combinations can be applied for each layer, i.e. for staple fiber roving (2) and yarn core (4).

These combinations are as follows:

Staple fiber roving (2) is dyed, yarn core (4) is undyed. Staple fiber roving (2) is dyed, yarn core (4) is dyed. Staple fiber roving (2) is undyed, yarn core (4) is dyed. Staple fiber roving (2) is undyed, yarn core (4) is undyed.

These combinations, which are realized during production, provide many different appearances to the core-spun yarn (7). Very diverse visual effects can be acquired in the core-spun yarn (7) produced out of staple fiber roving (2) and yarn core (4) dyed in different colors. In the textile product produced by this core-spun yarn (7), at the portions that wear out by time, i.e. the portions where the staple fiber roving (2) appearance is lost in patches, the yarn core (4) with a different color in the lower layer will be seen instead of the said appearance, and this will form a visual effect. The fact that the core-spun yarn (7) production can be realized in many different combinations allows for many diverse production options in textile products.

Core-spun yarn (7) production can be performed by combining dyed or undyed staple fiber roving (2) with yarn core (4) having coating process applied thereon. Thus, textile products coated with different purposes can be obtained. In the said production method, it is possible to obtain products for different purposes by applying different finishings to the yarn core (4).

Claims

1. A method (1) of producing ring dyeable core-spun yarn, comprising the steps of passing the staple fiber roving (2) between the aprons (3) (10), drawing of the yarn core (4) by the drawing rollers (5) (20), jacketing of the staple fiber roving (2) onto the yarn core (4) received from the core-spun yarn apparatus (8) (30), twisting the jacketed core-spun yarn (7) (40), and characterized in that the core-spun yarn (7) is wound onto the spindle (6) (50).

2. A method (1) of producing ring dyeable core-spun yarn according to Claim 1 , characterized by a core-spun yarn apparatus (8), which enables forming a jacketing layer in the form of a ring, by twisting and winding natural or dyed fiber (2), in a ring yarn machine, onto a yarn (4) which previously has been subjected to finishing and/or dyeing or which is natural, spun or filament.

3. A method (1) of producing ring dyeable core-spun yarn according to Claim 1 and 2, characterized in that it enables production of yarns thinner than NeB30 (NeB: British cotton yarn numbering system).

4. A method (1) of producing ring dyeable core-spun yarn according to Claim 1 to 3, characterized in that it enables production of woven and knitted torsion yarns.

5. A method (1) of producing ring dyeable core-spun yarn according to any of the preceding claims, characterized in that all kinds of staple or non-staple natural, artificial and synthetic fiber and strand groups are used.

6. A method (1) of producing ring dyeable core-spun yarn according to any of the preceding claims, characterized by a core-spun yarn apparatus (8) which enables production of knitted torsion yarn which can be indigo dyed.

7. A method (1) of producing ring dyeable core-spun yarn according to any of the preceding claims, characterized by a core-spun yarn apparatus (8) which enables combining of natural, artificial, synthetic strand mixtures with the same or different fiber mixtures.

8. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining dyed staple fiber roving (2) with undyed yarn core (4).

9. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining dyed staple fiber roving (2) with dyed yarn core (4).

10. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining undyed staple fiber roving (2) with undyed yarn core (4).

11. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining undyed staple fiber roving (2) with dyed yarn core (4).

12. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining undyed staple fiber roving (2) with yarn core (4) on which finishing is applied.

13. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining undyed staple fiber roving (2) with yarn core (4) on which hydrophobic finishing is applied.

14. A method (1) of producing ring dyeable core-spun yarn according to Claim 1 , characterized in that core-spun yarn (7) is produced by combining dyed or undyed staple fiber roving (2) with yarn core (4) on which fire retarding finishing is applied.

15. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining dyed or undyed staple fiber roving (2) with yarn core (4) on which a finishing is applied with therapeutic creams and ointments.

16. A method (1) of producing ring dyeable core-spun yarn according to Claim 1 , characterized in that core-spun yarn (7) is produced by combining dyed or undyed staple fiber roving (2) with yarn core (4) on which finishing is applied with materials that can be used as conductors.

17. A method (1) of producing ring dyeable core-spun yarn according to Claim 1, characterized in that core-spun yarn (7) is produced by combining dyed or undyed staple fiber roving (2) with coated yarn core (4).

Bibliography [1] ITKIB General Secretariat R & D and Regulations Branch, publication of June 2006.

[2] Prof. Isik Tarakcioglu, October 2007, 11^th International Izmir Textile and Ready Made Garments Symposium presentation.