WO2016016786A1

WO2016016786A1 - A yarn for woven fabrics

Info

Publication number: WO2016016786A1
Application number: PCT/IB2015/055613
Authority: WO
Inventors: Anup Kumar RAKSHIT; Subrata PALIT; Mahesh Sharma; Bhalchandra Ramchandra MANE
Original assignee: Reliance Industries Limited
Priority date: 2014-07-28
Filing date: 2015-07-24
Publication date: 2016-02-04

Abstract

The present disclosure relates to a yarn having shrinkage capacity in the range from 12 % to 15%. The yarn comprises a blend of a polyester fibre (A) having shrinkage capacity in the range of 20 % to 22 % at a temperature of 130^oC for 30minutes to 35 minutes and a polyester fibre (B) having shrinkage capacity in the range of 2 % to 3 % at a temperature of 130^oC for 30 minutes to 35 minutes, in the ratio ranging from 1:2 to 1:5. The present disclosure also relates to a woven fabric comprising the yarn of the present disclosure.

Description

A YARN FOR WOVEN FABRICS

FIELD:

The present disclosure relates to a yarn suitable for weaving fabrics. DEFINITIONS:

As used in the present disclosure, the following words and phrases are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.

The expression "high shrinkage" or "high shrinkable" for the purpose of the present disclosure includes a polymer having a shrinkage capacity of at least 20 %.

The expression the terms "low shrinkage" or "low shrinkable" for the purpose of the present disclosure includes a polymer having a shrinkage capacity below 20 %.

BACKGROUND:

Woven shawls and winter dress materials are bulky woven fabrics, particularly for protection from cold weather conditions. The desired bulk, thermal insulation or warmth in the woven fabrics/garments depends on its fibre constituent, yarn diameter and the level of yarn twist.

Traditionally, winter garments are made from wool fibres. The wool fibres can be replaced with acrylic fibres for economic reasons. However, with the increase in demand for acrylic fibres, acrylic fibres have also become substantially costlier. Therefore, the textile industry needs an alternative economic substitute for acrylic fibres. Various economic substitutes for acrylic fibres have been suggested.

EP 1860217 suggests a fabric prepared from two types of yarns that are different in self-elongating property upon absorbing water and is capable of facilitating air- permeability when wetted with water. The ratio of the first type of yarn to the second type of yarn is adjusted to 0.9 or less. JP2000220055 suggests a woven fabric consisting 3 wt% to 50 wt% fusing fiber, such as, a sheath-core fiber having low melting co-polyester and greater than 30 wt% highly shrinkable polyester staple fibers having 18 % to 80 % dry -heat shrinkage factor.

JP2002294534 suggests a bulky woven/knitted fabric consisting of a blend of high- shrinkage staple fibers having shrinkage factor greater than 40% and cellulosic staple fibers.

JPH06123057 suggests a woven fabric comprising spun yarn. The spun yarn is obtained from co-polyester short fibers A having 25 % to 70 % heat shrinkage percentage composed of a dicarboxylic acid component of terephthalic acid/isophthalic acid in a molar ratio of 96/4 to 88/12 and an ethylene glycol component with polyester short fibers B having 1 % to 3 % heat shrinkage.

Some of the suggested yarns/fabrics at least in partial amount contain acrylic acid, while others require specially treated raw material, due to which the suggested yarns/fabrics are still expensive. Further, the suggested polyester fibres also contain isophthalic acid. The presence of isophthalic acid in high amounts adversely affects the aesthetic appearance of the polyester, as it imparts color to the polyester. Still further, the yarn/fabric is either too bulky or cannot provide the desired level of warmth.

Therefore, there is felt a need for an economical yarn/fabric having desired shrinkage factor acid impurity and acceptable aesthetic appearance.

OBJECTS:

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

An object of the present disclosure is to provide a yarn suitable for weaving fabrics. Another object of the present disclosure is to provide a yarn which can be easily processed to achieve the desired dye depth.

Still another object of the present disclosure is to provide a yarn which can be used to at least partially substitute acrylic fibres or wool fibres.

Yet another object of the present disclosure is to provide a process for preparing a woven fabric.

Other objects of the present invention will be more apparent to a person skilled in the art from the description provided hereinafter.

SUMMARY:

Accordingly, the present disclosure provides a yarn suitable for weaving fabrics. The yarn of the present disclosure is economical, possesses a desired shrinkage factor and is capable of providing the desired warmth.

Particularly, the present disclosure provides a yarn having an acceptable level of shrinkage capacity suitable for weaving applications. The yarn is prepared from two types of polyester fibres (A and B) with different shrinkage factors/capacities, wherein the ratio of A to B ranges from 1:2 to 1:5.

DETAILED DESCRIPTION:

The present disclosure provides a yarn having shrinkage capacity in the range of 12 % to 15%. The yarn of the present disclosure is a blend of a polyester fibre (A) having shrinkage capacity in the range of 20 % to 22 % at a temperature of 130 °C for 30 minutes to 35 minutes, and a polyester fibre (B) having shrinkage capacity in the range of 2 % to 3 % at a temperature of 130 °C for 30 minutes to 35 minutes.

Numerous experiments were carried out to arrive at an optimum ratio of high shrinkage polyester fibre i.e., A and low shrinkage polyester fibre i.e., B. The optimum ratio of A to B ranges from 1:2 to 1:5. The polyester fibre having shrinkage capacity in the range of 20 % to 22 % is characterized by denier size in the range from 1.2 to 4, whereas the polyester fibre having shrinkage capacity in the range of 2 % to 3% is characterized by denier size in the range from 1.5 to 4.

The polyester fibres useful for the purpose of the present disclosure are made from at least one polymer selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate.

The yarn having a desired shrinkage capacity can be obtained by a process which involves bulking and dyeing A and B together in HT/HP (high temperature/high pressure) dyeing machine at 130 °C for 30 minutes to 35 minutes.

The process for obtaining yarn having a desired shrinkage capacity, may further comprise a step of disperse printing in a rotary or a flatbed printing machine.

The shrinkage capacity/factor of the yarn is the synergistic result of the ratio of the polyester fibres A and B, yarn twist capacity, thickness of the fibres and dyeing fibre in a single step in HT/HP jet dyeing machine.

The yarn used in a woven fabric of the present disclosure is obtained by the selection of a proper single and plied yarn twist levels, based on experimental data, followed by the selection of a suitable yarn bulking and dyeing hardware and process conditions. The optimized processing conditions include dyeing at a temperature of 130 °C and holding time of 30 minutes, bulking in high temperature/high pressure (HT/HP) dyeing machine at the 130 OC for 30 minutes, followed by Disperse Printing in Rotary or Flatbed Printing machine, drying at 150 °C and steaming at 170 °C for 6 minutes to 8 minutes in Steam Ager.

The present disclosure also provides a woven fabric comprising the yarn of the present disclosure.

The present disclosure is further illustrated herein below with the help of the following experiments. The experiments used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of embodiments herein. These laboratory scale experiments can be scaled up to an industrial/commercial scale.

Example 1:

Preparation of high shrinkage woven fabric

High shrinkable fiber having shrinkage 22 % and normal shrinkable fiber having shrinkage 3 % were blended in the proportion of 1:5 to obtain a yarn. Polyethylene terephthalate fibers were used to prepare the yarn and both the fibers were having denier of 3D each. Yarn twisting per inch was 2.8. The yarn was then converted into woven fabric by bulking in jet dyeing machine, then disperse printing in the flatbed printing machine, drying at 150 °C, followed by steaming at 170 °C for 8 minutes in steam ager. Final shrinkage of the woven fabric was 15 %.

Shrinkage of the fiber is determined by first measuring the pre-tensioned fiber length. The fiber is then subjected to a temperature of 130 °C for 30 minutes. The fiber length is then measured under tension. The difference in the length of the fiber as compared to the initial length is determined and the percent shrinkage is calculated.

The shrinkage for a fabric is measured in a similar way as mentioned for the fibers. The shrinkage of fabrics is measured in the warp way direction. The difference in the length of the fiber as compared to the initial length is determined and the percent shrinkage is calculated.

Example 2:

Preparation of high shrinkage woven fabric

High shrinkable PET fiber having shrinkage 22 %, denier 3D and normal shrinkable PET fiber having shrinkage 3 % and denier 3D were blended in the proportion of 1:2 to obtain a yarn. Yarn twisting per inch was 3.0. The yarn was then converted into woven fabric by bulking in jet dyeing machine, then disperse printing in flatbed printing machine, drying at 150 °C, followed by steaming at 170 °C for 6 minutes in steam ager. Final shrinkage of the woven fabric was 13 %.

In the conventional process for preparing acrylic fibers, yarn is first bulked then dyed in separate machines, followed by weaving. However, the bulking and dyeing of the fabric are simultaneously carried out in a single process in accordance with the present disclosure, leading to lower processing cost. The process of the present disclosure does not require any alteration or addition of downstream processing hardware and can easily be replicated in the downstream industry to produce bulked woven fabrics with soft handle and comfort, having superior aesthetic appearance.

TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCEThe yarn of the present disclosure described herein above has several technical advantages including, but not limited to, the realization of:

- a yarn suitable for weaving fabrics; and

- a yarn having an improved aesthetic appearance.

The yarn prepared by the process of the present disclosure does not require any further downstream processing hardware.

Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values ten percent higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Claims

A yarn comprising a blend of a polyester fibre (A) having shrinkage capacity in the range of 20 % to 22 % at a temperature of 130 °C for 30 minutes to 35 minutes and a polyester fibre (B) having shrinkage capacity in the range of 2 % to 3 % at a temperature of 130 °C for 30 minutes to 35 minutes;

wherein, the shrinkage capacity of the yarn ranges from 12 % to 15%; and

the weight ratio of A to B ranges from 1 : 2 to 1 : 5.

The yarn as claimed in claim 1, wherein the polyester fibres A and B are made from at least one polymer selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate.

The yarn as claimed in claim 1, wherein the polyester fibre having shrinkage capacity in the range of 20 % to 22 % is characterized by denier size in the range from 1.2 to 4.

The yarn as claimed in claim 1, wherein the polyester fibre having shrinkage capacity in the range of 2 % to 3% is characterized by denier size in the range from 1.5 to 4.

A woven fabric comprising the yarn as claimed in claim 1.