DESC:TECHNICAL FIELD
[001] The present invention relates to a method for manufacturing an engineered yarn having uniformly distributed hollow pockets. The present invention also relates to a method for producing a fabric product comprising the engineered yarn and having superior bulk, enhanced absorbency, enhanced softness and thermal insulation.

BACKGROUND OF THE INVENTION
[002] Fabric products used in various applications, such as towelling, rugs, bedding, and leisure fabrics, are preferred to have high moisture absorbency, high bulk and soft hand feel. These fabrics are usually made with cellulosic fibres and are often designed to maximize the absorptive properties of the fabric.
[003] Towels are generally thick textile articles with a piled surface (i.e., looped surface) on the front and/or back of the fabric. Thicker towels typically have a deeper pile with a greater surface area. This increased surface area generally increases the absorption properties of the fabric. For example, when a terry towel fabric contacts a water droplet, the pile loops first remove the droplet by drawing the droplet into the spaces between the fibres in the yarn. Water is then wicked throughout the length of the pile and into the ground weave of the fabric. Further, once water is drawn into the yarn, it may be absorbed into the lumen of the cotton fibre. The density of the fibres in the yarn impacts the yarn’s ability to dry; this in turn impacts the yarn’s ability to absorb more water.
[004] Generally, woven fabrics are made with two sets of yarns: the warp and the weft; however, terry fabrics are generally formed with three sets of yarns. The first set is a ground warp which is a longitudinal set of yarns forming the ground fabric. The second set, a pile warp, is a set of longitudinal warp yarns that are used to form the loop piles on the fabric surface. The third set, a weft yarn, forms the transverse yarn that interlaces with the ground and the pile warps to form the fabric. Any of these two (or three) sets of yarns, and the resulting fabric, may be designed to absorb water.
[005] While cellulose and cotton fibres are generally preferred due to their desirable properties (for example, softness, absorptive properties, and sustainability), there is a desire to further increase the absorptive properties of a fabric used in applications such as towel, rugs, bedding, and leisure fabrics.
[006] It is further observed that the amount of twist in the yarn also affects the properties of the towel products. The pile yarn is generally a low-twist yarn. Pile loops provide maximum surface area for the absorption of water, and the low twist aids in the absorption by imparting wicking properties to the yarn. Ground warp and weft are generally hard twisted compared to the pile yarn. The ground and weft yarn twist factors generally range from about 3.8 to about 4.2, depending upon the towel construction. In contrast, the twist factor in the pile yarn generally ranges from about 3.2 to about 3.8. Similarly, in the case of flat fabrics the twist factor for warp and weft ranges from about 3.8 to about 4.5.
[007] Normally the yarns used in terry fabrics are coarse and range from Ne (Number English) 6s to 40s (98.33 Tex to 14.75 Tex) in single as well as doubled configuration for pile, weft, and ground yarns. The coarse yarn has a greater number of fibres in the cross section. Similarly, the warp and weft yarn count, in the case of flat fabrics range from Ne 12s (49.20 Tex) to Ne 140s (4.21 Tex) in single as well as doubled configuration depending on the construction.
[008] The yarns used in terry fabrics are typically all cotton except for yarns used in decorative designs and embellishments on the fabric. Decorative designs and embellishments are formed using polyester filament, polyester spun yarn, viscose filament yarn, viscose spun yarn, mercerized cotton yarn, modal yarns, chenille yarn, modified viscose yarn, and combinations thereof. Other flat fabrics such as sheeting are made from 100% cotton; blends of polyester and cotton; blends of polyester and viscose: blends of cotton and modal, blends of cotton and silk and modal; blends of cotton and bamboo: blends of cotton and seaweed fibres; blends of cotton and silver fibres; blends of cotton and charcoal fibres; and any combinations thereof.
[009] The greater the amount of free air space available within the yarn, the quicker and increased absorption of water. Hence, to increase the amount of free space, (similarly as the air space increases the drying of the towel after absorption also increases) structural changes in the yarn must be made.
[010] Conventional method for making engineered yarns having high wettability and quick absorbency require blending soluble and insoluble fibres in the yarn, followed by dissolving the soluble fibres to produce air gaps in the bulk of the yarn. However, this method produces a high degree of unevenness in the yarn due to uneven blending of soluble and insoluble fibres resulting in a considerable number of places along the yarn that are significantly thicker or thinner than average. Thus, leading to increased chances of breakage at thin places or clumping at thick places.
[011] US11486065B2 discloses a method of blending soluble fibres with insoluble fibres to produce yarns, followed by dissolving the soluble fibres to produce hollow core yarn. The yarn structure obtained herein has a hollow core on the interior and extends axially along the length of the yarn.
[012] While presently known methods provide many desirable properties such as softness, absorptive properties, and sustainability, there is a desire to further increase the absorptive properties of a fabric used in applications such as towelling, rugs, bedding, and leisure fabrics. Furthermore, the existing techniques are also limited in terms of the number of materials that may be blended to obtain a fabric, thereby limiting the performance and characteristic of such fabrics.
[013] Thus, there is a need in the art for an improved method for producing a yarn and fabrics made from such yarns, which address at least the aforementioned problems.

SUMMARY OF THE INVENTION
[014] An aspect of the present invention is directed to a method for producing a yarn. The method comprises subjecting at least one primary fibre in a drawing unit to obtain a sliver of primary fibre; subjecting at least one soluble fibre in a drawing unit to obtain a sliver of soluble fibre; blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit to obtain a first blended sliver; and drawing the first blended sliver in a drawing unit along with the sliver of soluble fibre and optionally a combed primary sliver to obtain a second blended sliver. The method also comprises spinning a roving of second blended sliver or the second blended sliver in a yarn spinning unit to obtain the yarn.
[015] In an embodiment, the combed primary sliver is obtained by lapping the sliver of primary fibre in a lapping unit to obtain form a primary sliver and combing the primary sliver in a combing unit to obtain produce the combed primary sliver.
[016] In another embodiment, the roving of second blended sliver is obtained by passing the second blended sliver through a speed frame roving unit.
[017] In another embodiment, the first blended sliver and/or the second blended sliver is optionally subjected to one or more drawing units, along with one or more sliver of primary fibre, sliver of soluble fibre and combed primary sliver.
[018] Another aspect of the present invention relates to the yarn produced by the above method. The yarn comprises 5 wt.% to 60 wt.% of at least one soluble fibre and is characterized in that: (i) a degree of unevenness in the yarn after spinning ranges between 8.5% to 10% and reduces to a range between 7% to 8% after subjecting the yarn to a wet processing step, the degree of unevenness being determined by Uster Test; (ii) thin places in the yarn after spinning range between 3500 to 5000 per 1000 meter and reduce to a range between 3000 to 4000 per 1000 meter after the wet processing step; (iii) thick places in the yarn after spinning range between 2000 to 2200 per 1000 meter and reduce to a range between 2000 to 2100 per 1000 meter after the wet processing step; and (iv) extra thick places in the yarn after spinning range between 150 to 350 per 1000 meter and reduce to a range between 50 to 100 per 1000 meter after the wet processing step.
[019] In an embodiment, the wet processing step is carried out in presence of one or more chemicals selected from the ground consisting of a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer / buffer, water, solvent, and levelling agent.
[020] In another embodiment, the at least one primary fibre is selected from the group consisting of cotton, linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (sustainable or recycled), polylactic acid (PLA), polybutylene terephthalate (PBT), nylon, acrylic, and mixtures thereof.
[021] In another embodiment, the at least one soluble fibre is selected from a polyvinyl alcohol (PVA), wool, silk, co-polymer of polyester, bio-based compostable and biodegradable fibers, bio-based non-compostable and non-biodegradable fibers, non-bio-based compostable and biodegradable fibers, non-bio-based non-compostable and non-biodegradable fibers, and mixtures thereof.
[022] Another aspect of the present invention relates to a method for producing a fabric. The method comprises subjecting at least one primary fibre in a drawing unit to obtain a sliver of primary fibre; subjecting at least one soluble fibre in a drawing unit to obtain a sliver of soluble fibre; blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit to obtain a first blended sliver; drawing the first blended sliver in a drawing unit along with the sliver of soluble fibre and optionally a combed primary sliver to obtain a second blended sliver; spinning a roving of second blended sliver or the second blended sliver in a yarn spinning unit to obtain the yarn; and weaving or tufting the yarn to obtain the fabric.
[023] In an embodiment, prior to weaving or tufting, the yarn is wound into packages, optionally in an autoconer unit, and then subjected to a plying unit.
[024] In yet another embodiment, the fabric is subjected to wet processing in the presence of one or more chemicals selected from the group consisting of a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer or a buffer, and levelling agent.
[025] In another embodiment, the tufting is carried out in a tufting unit, whereby the yarn is stitched or punched on a base material fibre.
[026] Yet another aspect of the present invention relates to a fabric made from the above yarn. The fabric comprises a blend of at least one primary fibre and at least one soluble fibre. Further, the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre homogeneously distributed with the primary fibre.
[027] In an embodiment, the fabric is selected from the group consisting of a tufted fabric, a terry fabric, and a flat fabric.
[028] In another embodiment, the fabric is used to make a textile product selected from the group consisting of a bedsheet, terry towel, carpet, area-rug, bathrobe, sheeting, and apparel.

BRIEF DESCRIPTION OF FIGURES
[029] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a process flow diagram of a method for producing a yarn in accordance with an embodiment of the present invention.
Figure 2 illustrates a process flow diagram of a method for producing a yarn in accordance with another embodiment of the present invention.
Figure 3 illustrates a diagram of the Greige Yarn in accordance with another embodiment of the present invention.
Figure 4 illustrates a diagram of the Yarn after Wet Processing in accordance with another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[030] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[031] The present invention broadly relates to the field of textile engineering, more specifically to manufacture of an engineered yarn. Embodiments of the present invention are directed towards a method of production of a blended yarn having high absorbency and homogeneity, and towards fabrics made thereof.
[032] In the present context, “absorbency” refers to the propensity of a fabric to take in and retain liquid, usually water.
[033] “Blend” refers to a textile containing two or more different fibres, including slivers, such as variants of the same fibre or different colours and grades of the same fibre.
[034] “Blowroom” as used herein refers to a mechanism that utilizes controlled air currents to open and separate fibres.
[035] “Count”, also called Number English (Ne) refers to the number of hanks of 840 yards per pound.
[036] “Carding” refers to the process in manufacturing spun yarn in which the fibres are separated, distributed, equalized and formed into a web. The web can be very thin or thick. The process of carding removes some impurities, and a certain amount of short or broken fibres. Suitable speed at which a card is operated ranges between 35 kg/h to 45 kg/h, which is 15 to 20 % lower than regular speed of card for soluble fibres.
[037] “Lapping” refers to a method where multiple slivers of the primary fibre being aligned and combined to create a single, uniform primary sliver before further processing. The lapping of slivers typically involves feeding several individual slivers into a machine or device that aligns them side by side.
[038] “Combing” refers to method for preparing carded fibre for spinning by aligning the fibres in parallel before spinning to produce a smoother, stronger, and more lustrous yarn. The process of combing is accompanied by gilling, a process of evening out carded or combed top making it suitable for spinning.
[039] “Degree of unevenness” is a measure of variation in weight per unit length of the yarn or the variation in thickness of the yarn, as measured by capacitive methods in an Uster Testing machine. Versions of the specific test standards utilised herein are identified in table 1 and table 2.
[040] “Denier” refers to the thickness of a fibre. It is the measurement of the diameter of the fibre and refers to weight in grams for 9000 meters of fibre.
[041] “Elongation” refers to the stretching of a fibre or yarn under tension as a percentage of its original length.
[042] “GSM” stands for grams per square meter (g/m2). It is the weight of 1 meter square of fabric in grams.
[043] “Hairiness Index” (H.I.) refers to the number of protruding fibres in a unit length of yarn that extends beyond the set length.
[044] “Hank” refers to a definite length of textile material that varies according to the material. For instance, a hank of wool is 560 yards, cotton and silk is 840 yards, and linen is 300 yards.
[045] Tex is another measure of yarn thickness, where in the weight in grams of 1000 m of yarn/fibre is called Tex.
[046] “Pile” is the surface effect on a fabric formed by tufts or loops of yarn that stand up from the body of terry fabrics.
[047] “Plying” refers to a textile process that involves twisting multiple strands of yarn together to create a stronger, more uniform yarn.
[048] “Roving” refers to a long and narrow bundle of fibre produced during the process of making spun yarn.
[049] “Sliver” refers to a continuous strand of loosely assembled fibres without twist that have been carded or combed to some extent but remain relatively loose and unspun. Sliver is an intermediate product in the process of converting raw fibres into yarn. The production of the sliver is the first step in the textile operation that brings the staple fibre into a form that can be drawn and eventually twisted into a spun yarn.
[050] “Spinning” refers to the final step in the production of yarn. The twisting of fibres in the form of the sliver or roving.
[051] “Tufting” is the process of textile manufacturing in which a thread is inserted on a primary base. This imparts thickness and surface effect to the material and is commonly used for rugs.
[052] “Warp” are yarns, in woven fabric, that run lengthwise and are interwoven with the fill (weft) yarns.
[053] “Weft” is filling yarns, in woven fabric, that run perpendicular to the warp yarns.
[054] “Yarn” refers to a continuous strand of textile fibres created when a cluster of individual fibres are twisted around one another.
[055] An aspect of the present invention is directed towards the method for producing a yarn.
[056] In an embodiment, the method comprises the steps of:
subjecting at least one primary fibre (optionally combed) in a drawing unit 109 to obtain a sliver of primary fibre;
subjecting at least one soluble fibre in a drawing unit 113 to obtain a sliver of soluble fibre;
blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit 111 to obtain a first blended sliver;
drawing the first blended sliver in a drawing unit 114 along with the sliver of soluble fibre and a combed primary sliver (optionally combed) to obtain a second blended sliver, and
spinning a roving of second blended sliver in a yarn spinning unit 116 or spinning the second blended sliver
[057] In another embodiment, the method comprises the steps of:
subjecting at least one primary fibre (optionally combed) in a drawing unit 109 to obtain a sliver of primary fibre;
subjecting at least one soluble fibre in a drawing unit 113 to obtain a sliver of soluble fibre;
blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit 111 to obtain a first blended sliver;
drawing the first blended sliver in a drawing unit 114 along with the sliver of soluble fibre and optionally a combed primary sliver (optionally combed )to obtain a second blended sliver,
the second blended sliver obtained from drawing unit 114 passes through spinning unit 120 to obtain the yarn.
[058] In an embodiment, the at least one primary fibre is selected from the group consisting of a cotton, linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (Virgin or recycled), polylactic acid (PLA), polybutylene terephthalate (PBT), nylon, acrylic, and mixtures thereof.
[059] In another embodiment, the at least one soluble fibre is selected from the group consisting of a polyvinyl alcohol (PVA), wool, silk, co-polymer of polyester, bio-based compostable and biodegradable fibers, bio-based non-compostable and non-biodegradable fibers, non-bio-based compostable and biodegradable fibers, non-bio-based non-compostable and non-biodegradable fibers, and mixtures thereof. As used herein, the term "bio-based" is synonymous with "renewable", whereas "non-bio-based" refers to "non-renewable" or "fossil fuel-based".
[060] In another embodiment, the at least one primary fibre, and the at least one soluble fibre, independent of each other, may be a virgin fibre, recycled fibre, or a combination thereof. Herein, the term "virgin fibre" typically denotes fibres that have not been previously used or recycled. Said otherwise, these fibres have not undergone any processing or treatment beyond their initial production. Herein, the term "recycled fibre" typically denotes fibres that have been previously used and reprocessed. In other words, these fibres have undergone a process of reclaiming and repurposing, typically from post-consumer or post-industrial waste, to be reused in new products.
[061] Referring to Figures 1 and 2, the method includes receiving the at least one primary fibre from a source 101 and subsequently storing in a storage unit 102. Similarly, the at least one soluble fibre is received from a source 104 and stored in a storage unit 107. The at least one primary fibre and the at least one soluble fibre are separately received from suppliers and stored in separate storage facilities which are well known to a person skilled in the art. Such storage facilities are preferably sealed, and climate controlled to ensure fibres do not accumulate excess moisture from the environment.
[062] While the storage 102 is preferably sealed and climate controlled to avoid any moisture ingress therein, it may be possible that the storage 102 includes at least one soluble fibre. In such cases, a premix of the at least one primary fibre and the at least one soluble fibre is subjected to further processing, as described herein below. Similarly, the storage 107 may also include at least one insoluble fibre or at least one primary fibre along with the at least one soluble fibre, thereby forming a premix which is subjected to further processing, as described herein below.
[063] In an embodiment, prior to the mixing or blending the at least one primary fibre in the drawing unit 111, the at least one primary fibre is processed through a blowroom unit 103, a carding unit 106, a lapping unit 105, a combing 108 and a drawing unit 109, whereby slivers of the at least one primary fibre are obtained. Said otherwise, slivers of primary fibre are obtained.
[064] In another embodiment, prior to the mixing or blending the at least one soluble fibre in the drawing unit 111, the at least one soluble fibre is processed through a blowroom unit 110, a carding unit 112, and a drawing unit 113, whereby slivers of the at least one soluble fibre are obtained. Said otherwise, slivers of soluble fibre are obtained.
[065] The soluble fibres are made into soluble slivers through the process of carding 112 and drawing 114 (one or two passages as required in order to ensure uniformity of fibres in the stream). Soluble sliver of suitable hank is obtained here, for e.g., 0.05 (11800 Tex) to 0.40 (1480 Tex). The hank being the weight per unit length of the soluble sliver as per the number English System of Count Notation.
[066] Accordingly, in an embodiment, the method comprises mixing or blending the sliver of primary fibre with the sliver of soluble fibre in the drawing unit 111 to obtain a first blended sliver. The present invention is not limited by any specific configuration and/or arrangement of these slivers (both primary and soluble). In an exemplary embodiment, the slivers of soluble fibre are blended with the slivers of primary fibre in a manner that one or more slivers of soluble fibre are always placed in the centre and the slivers of primary fibre are placed on the sides the soluble slivers. Further, reference to “slivers” in the present context is intended to refer to a plurality of slivers. Furthermore, the present invention is not limited by the number of slivers. The number of slivers (both primary and soluble fibres) is dependent on the type of fabric being produced. Accordingly, it is within the purview of the person skilled in the art to make suitable selections with regard to configuration and number of slivers to achieve a desired fabric.
[067] In the present context, drawing represents the broader process of preparing fibres for spinning, which includes various stages such as carding, combing, and drawing itself. The drawing unit is a crucial component within this process. The drawing unit further aligns and elongates the fibres after carding or combing, but before spinning them into yarn. During the drawing stage, the drawing unit stretches the sliver, reducing its thickness and increasing its length. This action aligns the fibres more uniformly, removes remaining impurities, and creates a consistent strand of fibres known as roving, which is then spun into yarn.
[068] In an embodiment, the first blended sliver from the drawing unit 111 along with soluble fibre and optionally combed primary sliver subjected to a further drawing unit 114 along with the sliver of soluble fibre and optionally the combed primary sliver to obtain the second blended sliver. The optional blending of the combed primary sliver in the drawing unit 114 is represented by dotted lines in Figures 1 and 2. Combing of the primary slivers in the combing unit 108, obtained from the lapping unit 105, ensures that any short fibre, called noils, and other impurities from the fibre mass are removed, thereby improving the quality and uniformity of the yarn. Combing further results in alignment and parallelization of the slivers, to enhance the strength and smoothness of the yarn. Accordingly, coarser count (Ne ranging between 2s (295.25 Tex) to 16s (36.90 Tex)) do not necessarily require the combing unit 108 and therefore the blending in the drawing unit 114 is between the first blended sliver and the sliver of soluble fibre.
[069] In another embodiment, the first blended sliver from the drawing unit 111 is subjected to a further drawing unit 114 along with the sliver of soluble fibre and the combed primary sliver to obtain the second blended sliver. Herein, the sliver of soluble fibre from the drawing unit 113 is directly blended with a stream of combed primary sliver obtained from a combing unit 108. Accordingly, in an embodiment, the combed primary sliver is obtained as follows:
lapping the sliver of primary fibre in a lapping unit 105 to form a primary sliver, and
combing the primary sliver in the combing unit 108 to produce the combed primary sliver.
[070] Lapping results in multiple slivers of the primary fibres being aligned and combined to create a single, uniform primary sliver before further processing. The lapping of slivers typically involves feeding several individual slivers into a machine or device that aligns them side by side. This alignment ensures that the fibres within each sliver are evenly distributed , thereby improving the overall consistency and quality of the resulting sliver.
[071] In another embodiment, the first blended sliver and/or the second blended sliver is optionally subjected to one or more drawing units, along with one or more sliver of primary fibre, sliver of soluble fibre, and combed primary sliver. The multi-step drawing and mixing/blending of soluble fibre with primary fibre in the present invention results in uniformity throughout the structure of yarn. This ensures open spaces in the fabric, thereby achieving desired characteristics like superior bulk, enhanced absorbency, enhanced softness and thermal insulation. Further, subjecting the slivers and/or the fibres to additional drawing units which may be placed before or after one or more of the drawing units 109, 111, 113, and 114 for achieving homogenous hollow pockets is well within the purview of the present invention.
[072] In yet another embodiment, as shown in Figure 1, the method further comprises passing the second blended slivers through a speed frame roving unit 115 to obtain the roving. Spinning the roving of second blended sliver in a yarn spinning unit 116 results in the yarn. The roving may be subjected to suitable spinning unit, such as a ring spinning unit or a friction spinning unit.
[073] Herein, the term "ring-spinning unit" refers to a traditional spinning system widely used in textile manufacturing. The ring spinning unit involves a series of machines where fibres are drawn, twisted, and wound onto a bobbin. The term "ring" comes from the rotating rings that guide the yarn formation during the method.
[074] In certain embodiments, the ring spinning step takes at least one soluble fibre sliver and at least one primary fibre sliver and turns it into a single yarn with S or Z twist keeping the twist multiplier in the range of 1.8 to 4.
[075] The spun yarn, from the ring spinning unit 116, is wound onto large packages by subjecting it to an autoconer unit 117, wherein the autoconer unit 117 winds the yarn onto a bobbin, followed by a plying unit 118, using suitable settings and process parameters depends on the yarn count. Further, the slivers from the drawing unit 114 may be subjected to suitable spinning units like open end spinning like rotor spinning, air-jet spinning, followed by the autoconer unit 117 and the plying unit 118.
[076] In another embodiment, as shown in Figure 2, the second blended slivers are directly subjected to a spinning unit 120 to obtain the yarn. Herein, the spinning unit 120 is an open-end spinning unit or an airjet spinning unit. Both the open-end spinning unit and the airjet spinning unit bypass the speed frame roving unit 115 and the autoconer unit 117.
[077] As is known to the person skilled in the art, open-end spinning, also known as rotor spinning, is a method of producing yarn directly from slivers. In this technique, fibers are fed into a rotor where they are separated, aligned, and subsequently twisted to form a continuous yarn.
[078] Air-jet spinning is an advanced spinning technique that utilizes high-speed jets of air to twist and bond fibers into yarn. The process starts with slivers, which are drawn and drafted to the desired thickness before being subjected to the action of compressed air.
[079] The yarn from the spinning unit 120 is wound directly into packages, thereby making the process efficient and cost-effective.
[080] The drawing units 111 and/or 114, ensure that the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre adjusting hank of sliver . Further, the yarn count obtained from the present invention ranges between Ne 3s (196.83 Tex) to 80s(7.38 Tex).
[081] Another aspect of the present invention relates to a yarn obtained from the above method. Accordingly, the embodiments pertaining to the method are applicable here as well.
[082] In an embodiment, the yarn comprises a blend of the at least one primary fibre and the at least one soluble fibre, as described above. Moreover, the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre.
[083] In another embodiment, the method may further comprise of a wet processing step to a fabric, wherein the wet processing step is carried out in presence of one or more chemicals selected from a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer or a buffer, and levelling agent.
[084] In yet another embodiment, the yarn has a degree of unevenness after spinning ranges between 8.5% to 10% and reduces to a range between 7% to 8% after subjecting the yarn to a wet processing step, the degree of unevenness being determined by Uster Testing machine. The degree of unevenness measures variation in weight or thickness per unit length of the yarn or the variation in thickness of the yarn, as measured by capacitive methods.
[085] In another embodiment, the yarn after spinning has 3500 to 5000 thin places per 1000 meters which reduce to between 3000 to 4000 places per 1000 meters after wet processing.
[086] In yet another embodiment, the yarn after spinning has 2000 to 2200 thick places per 1000 meters which reduce to between 2000 to 2100 places per 1000 meters after wet processing.
[087] As is known to the person skilled in the art, a thin place is categorised as a location in the yarn having diameter at least 30% less than the average diameter of the yarn. Similarly, a thick place is categorised as a location in the yarn having diameter at least 30% greater but not more than 200% greater than the average diameter of the yarn. An extra-thick place is categorised as a location in the yarn having diameter at least 200% greater than the average diameter of the yarn.
[088] In an embodiment, prior to weaving or tufting, the yarn is wound into packages, optionally in an autoconer unit 117, and then subjected to a plying unit 118. As discussed hereinabove, the autoconer unit 117 is required for the yarn spinning unit 116. Further, the yarn spinning unit 120 bypasses the autoconer unit 117.
[089] As shown in Figures 1 and 2, the yarn after being subjected to the plying unit 118 is sent to a winding unit 119, where it is wound onto packages. The yarn is wound on various types of packages such as tubes, wheels, bobbins, spools and/or cones. Suitable winding units are known to the person skilled in the art.
[090] Unlike the conventional engineered yarns having single- or multi-core structure, the present invention, solubilizes soluble fibre to create uniformly distributed hollow pockets within the yarn. This process results in yarn with superior bulk, enhanced absorbency, increased softness, and improved thermal insulation properties for the fabric Accordingly, in an embodiment, the yarn is devoid of a single core structure or a multi-core structure. Herein, “core” is formed once the soluble fibre is dissolved.
[091] Yet another aspect of the present invention relates to a method for producing a fabric.
[092] In an embodiment, the fabric comprises at least one of the aforesaid yarn. Accordingly, the embodiments pertaining to the yarn are applicable here as well.
[093] In an embodiment, the method for producing the fabric comprises the steps of:
subjecting the at least one primary fibre in the drawing unit 109 to obtain the sliver of primary fibre;
subjecting the at least one soluble fibre in the drawing unit 113 to obtain the sliver of soluble fibre;
blending the sliver of primary fibre with the sliver of soluble fibre in the drawing unit 111 to obtain the first blended sliver;
drawing the first blended sliver in the drawing unit 114 along with the sliver of soluble fibre and optionally the combed primary sliver to obtain the second blended sliver;
spinning the roving of second blended sliver in the yarn spinning unit 116 or spinning the second blended sliver in the yarn spinning unit 120 to obtain the yarn; and
weaving or tufting the yarn to obtain the fabric.
[094] In an embodiment, the fabric is selected from the group consisting of a tufted fabric, a terry fabric, and a flat fabric. The term "weaving" as used herein refers to a process of fabric production that involves interlacing two sets of yarn - the warp, and the weft, to create a woven fabric. The warp yarns run lengthwise, and the weft yarns run crosswise, forming a stable and structured textile. In this regard, the yarn obtained from the spinning unit is subjected to weaving, where the yarn is threaded onto a loom. The loom facilitates the interlacing of the warp and the weft yarns, creating the woven fabric. The weaving imparts strength, structure, and durability to the fabric. The interlacing of the yarns creates a cohesive textile that can be used for a wide range of applications, from clothing to household textiles. During the weaving, the fabric is made in air jet loom and for terry cloth two beam warp sheet such as ground and Pile is used. And for the flat cloth one beam warp sheet is used. For terry cloth different GSM for 200 to 1800 in 3, 4, 6 pick terry and their derivatives in dobby / jacquard design and for flat fabric from 100 to 1000 GSM fabric made with pain, twill, satin, and their derivative in dobby/ jacquard design.
[095] In another embodiment, the tufting is carried out in a tufting unit, whereby the yarn is stitched or punched on a base material fibre. The term "tufting" as used herein refers to an alternative method of creating fabrics, often used for producing rugs, carpets, and similar products. In tufting, the yarn is stitched or punched through a base material, creating loops or tufts on one side and a smooth surface on the other. The yarn is utilized in tufting by feeding it through a tufting unit. The tufting unit punctures the base material, creating loops or tufts on one side. The length and density of the tufts can be controlled, allowing for various textures and designs. It will be appreciated that the tufting provides versatility in texture and design, making it suitable for products such as the rugs and the carpets. The tufting is performed in 250 to 2500 GSM range.
[096] Optionally, warping is performed before weaving of the yarn into the fabric. During warping, a warp sheet is made for the loom. Moreover, a sizing agent may be applied to enhance the weaveability properties, especially strength, lubrication, and binding properties. In flat cloth, warp sheet, and terry cloth ground the pickup ranges between 7% to 10% and for Pile sheet it ranges between 3% to 5%.
[097] Yet another aspect of the present invention relates to a fabric produced by the above process, wherein the fabric is composed of a yarn comprising a blend of at least one primary fibre and at least one soluble fibre, wherein the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre.
[098] The method further comprises subjecting the fabric obtained post weaving to wet processing. In an embodiment, the fabric may be treated with suitable chemicals known to the person skilled in the art during wet processing. These chemicals include, but are not limited to, wetting agent (ionic and non-ionic both), desizing agent (such as a protease type enzyme), hydrogen peroxide stabilizer (anionic or commercially available), lubricant, core alkali neutralizer or a buffer (anionic or commercially available), and levelling agent (anionic or commercially available).
[099] Wet processing refers to a series of steps that treat textiles with various chemicals and colorants to improve their performance and appearance. Textile wet processing, which includes but is not limited to pretreatment, desizing, scouring, bleaching, dyeing, or printing, and finishing, is of crucial importance for improving the performance and serviceability of textile materials. Herein, desizing includes removal of sizing agents applied during weaving for smoother fabric. Scouring includes cleaning to eliminate impurities, waxes, and natural oils from the fabric. Bleaching includes whitening the fabric by removing colour impurities. Dyeing includes applying colour to the fabric for desired aesthetics. Printing includes adding patterns or designs onto the fabric. Finishing includes final treatments to improve texture, feel, and durability. Wet processing imparts textiles the desired characteristics, such as colour, softness, water repellence, wrinkle resistance, and durability.
[0100] In an embodiment, the yarn or fabric made therefrom is subjected to one or more wet processing steps, wherein the wet processing step is carried out in presence of one or more chemicals selected from the ground consisting of a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer or a buffer, water, solvent, and levelling agent. Moreover, the wet processing is typically carried out in specialized machinery designed for each treatment stage. The various chemicals and dyes are applied at specific stages according to the treatment requirements. The wet processing enhances fabric qualities, improving softness, colour vibrancy, and overall aesthetics.
[0101] Figure 3 illustrates a diagram of a Greige Yarn in accordance with another embodiment of the present invention. The greige yarn depicted in the diagram comprises a combination of both soluble fibres (SF) and insoluble fibres (IF), which contribute to the yarn's unique properties. The soluble fibres (SF) are designed to dissolve under specific conditions, while the insoluble fibres (IF) retain their structural integrity and provide bulk and absorbency to the yarn. This hybrid composition may allow for a range of functional applications, as the soluble fibres (SF) may be engineered to dissolve when exposed to wet processing.
[0102] Figure 4 illustrates a diagram of the Yarn after Wet Processing in accordance with another embodiment of the present invention. The greige yarn depicted in the diagram only includes insoluble fibers (IF) after wet processing. After undergoing the wet processing treatment, the greige yarn depicted in the diagram exclusively includes insoluble fibres (IF), with the soluble fibres having been removed or dissolved during the wet processing. This selective removal of soluble fibres is achieved through the wet processing.
[0103] In an embodiment, wet processing for obtaining a flat or terry cloth is carried out through continuous or exhaust process in long length fabric form. However, in case of bath rugs, wet processing may be carried out in in rope form using exhaust process and/or one-piece using paddle dyeing machine.
[0104] The present invention also provides for a method for production of various types of fabrics containing at least the aforesaid yarn. Optionally, the fabric may be cut into patterns based on the product type. Optionally, the fabrication process includes sewing the fabric's pieces together to form the final textile product. The made-up fabric obtained here is the finished textile product or the fabric that is ready for use. Such fabrics include, but are not limited to, bedsheet, terry towel, carpet, area-rug, bathrobe, sheeting, apparel or any variations thereof.
[0105] Advantageously, the present invention provides a method for producing an engineered yarn wherein the soluble fibre(s) are homogeneously distributed with the primary fibre, thereby resulting in a yarn which, after wet processing, possesses superior bulk, enhanced absorbency, enhanced softness and thermal insulation. Further, the yarn also has increased air space or hollow pockets which need not necessarily be in the core but distributed homogeneously throughout the bulk of the yarn. Furthermore, the fabric produced by the present invention exhibits superior bulk, soft hand feel, and enhanced moisture absorption capacity per unit weight of the fabric. Moreover, the fabric exhibits improved properties of bulkiness, absorbency, thermal insulation, and softness, compared to normal fabric with wash.

EXAMPLE
[0106] The following examples are illustrative of the invention but not limitative of the scope thereof.
[0107] Production of Yarn
[0108] Yarn AG – A sample of yarn was produced in accordance with the embodiments of the present invention using cotton as the primary fibre and PVA fibre as soluble fibre. The cotton fibre was drawn in the drawing unit 109 to obtain a sliver of cotton fibre. Similarly, the PVA fibre was drawn in the drawing unit 113 to obtain a sliver of PVA fibre. The slivers of cotton fibre and PVA fibre were blended by drawing in the drawing unit 111 to obtain the first blended sliver. Subsequently, the first blended sliver was drawn in the drawing unit 114 along with the sliver of PVA fibre and the combed primary sliver to obtain the second blended sliver. Lastly, roving of the second blended sliver was spun in the yarn spinning unit 116 resulted in yarn AG.
[0109] Yarn BG – Another yarn was prepared using conventional method of draw frame blending the PVA and cotton fibres. For this, cotton fibre was drawn in the drawing unit to obtain a sliver of cotton fibre. Separately, the PVA fibre was drawn in the drawing unit to obtain a sliver of PVA fibre. Thereafter, the sliver of cotton fibre and the sliver of PVA fibre were blended by drawing in a drawing unit to obtain a blended sliver. Lastly, a roving of the blended sliver was spun in the yarn spinning unit to obtain the yarn BG.
[0110] Wet Processing
[0111] The above-produced greige yarns AG and BG were subjected to wet processing to solubilize the PVA fibre and obtain Yarns AS and BS respectively.
[0112] Comparative Testing
[0113] Yarns AG, AS, BG and BS were analysed for several parameters in accordance with the Uster Test machine. The result of the yarns is documented in Table 1 below. In below table the Uster test report is given where it’s clearly shown the yarn with the claim process is having more uniform and less degree of unevenness, thick /thin place this is due to homogenous blend of soluble fibre. Where in case of BS the data are reverse showing more unevenness, more thick and thin places then greige yarn.
[0114] Table 1: Comparative analysis of the yarn samples
PARAMETER UNIT YARN AG YARN AS YARN BG YARN BS
Degree Of Unevenness
(ASTM D1425) % 8.5-10 7-8 10.2 – 12 19 - 25
Thin Place Number/1000m 3500-5000 3000-4000 6500 – 9000 10000 - 15000
Thick Place Number/1000m 2000-2200 2000-2100 2500 – 3500 6000 - 9000
Extra Thick Place Number/1000m 150 - 350 50 - 100 350 – 550 500 - 800
Protruding Fiber HI 8.0 – 10.5 6 – 7 10.5 – 11 12 - 15
Single Yarn Strength
(ASTM D2256) RKM 17.5 – 18.5 13 - 15 16.5 - 17 8 - 11
CV, % 8 - 10 5- 6 11 - 12 11- 12
Elongation EL, % 5.5 – 6.5 5.5 – 6.5 5 - 6 5 – 6
Variation In Elongation EL CV, % 8 - 9 7 – 8 8.8- 9.8 10 – 12

[0115] The yarns AG and AS, produced in accordance with the present invention, display high wettability, quick absorbency, increased evenness, and homogeneity while reducing number of weak spots in the yarn. This is evident basis the variations in parameters between yarns AG to AS which is substantially lower than between yarns BG to BS.
[0116] Table 1 clearly shows that the yarn AS is more uniform and has less degree of unevenness as well as thick /thin place. This is due to homogenous blend of the soluble fibre. Whereas, in case of yarn BS the results demonstrate unevenness with more thick and thin places in the yarn.
[0117] Absorbency data
[0118] A 4-pick terry towel having dimensions 76 cm x 142 cm was tested for absorbency and bulkiness. The results are summarized in Table 2 below.
[0119] Table 2: Absorbency and bulkiness test
Property Pile warp sheet with 100% Cotton yarn (without soluble fibre) Pile warp sheet with 100% BG yarn Terry fabric made from present invention AG yarn
Surface Water Absorbency Before Wash
(ASTM D4772) -- -- --
After 3 Wash
(ASTM D4772) 60% 75% 83%
Bulkiness Test (After 3 Wash)
(AATCC-143)
Before Wash - 79 mm Before Wash -81 mm Before Wash - 83 mm
After wash - 85mm After wash - 92mm After wash - 98mm

[0120] As noted from Table 2, the terry fabric made from the present invention yarn has enhanced absorbency as well as bulkiness as compared to yarn obtained from a single draw frame blending.
[0121] Heat transfer and moisture properties of flat woven fabrics
[0122] The heat and moisture transfer properties can be determined in accordance with ASTM F 1868 - 17, Standard Test Method for Thermal and Evaporative Resistance of Clothing Materials Using a Sweating Hot Plate, Part C. This test is referred to herein as the “Thermal and Evaporative Resistance” test). Two exemplary flat woven fabrics were constructed and included the attributes illustrated in Table 3.
[0123] Table 3: Example Flat Woven Fabrics for Thermal and Evaporative Resistance Test
Example A B
Fiber Content Flat fabric made from 100% Cotton (without soluble fibre) Flat fabric made from the present invention yarn AG (with soluble fibre)
Thread Count 400 400
Warp Ne 80 80
Weft Ne 80 80
EPI 196 196
PPI 201 201
Weave Design Satin Satin
Weight(oz/yd2) 3.61 3.997
Thickness (mm) 0.23 0.23

[0124] The “Thermal and Evaporative Resistance” test is a measure of heat flow from the calibrated test plate (heated to a skin surface temperature of 35 degrees Celsius) through the flat woven fabric into the test environment (25 degrees Celsius, 65%RH). Heat flow is determined for both simulated dry and wet skin conditions. Heat loss parameters can be calculated from the following thermal transport measurements.
[0125] The total thermal resistance (Rct), [(?°C)(m2)/W], is the total resistance to dry heat transfer (insulation) for a fabric including the surface air layer. Total thermal resistance (Rct) is given by the following equation:
Rct = [(TS- Ta)·A]/[H],
where Ts is the temperature of the plate surface (35°C), Ta is the temperature in the local environment (25°C), A is the area of the test plate (0.01 m2), and W is the power input (W).
[0126] The intrinsic thermal resistance (Rcf), [(?°C)(m2)/W], is the resistance to dry heat transfer provided by the fabric alone. Intrinsic thermal resistance (Rcf) is determined by subtracting the average dry bare plate resistance (Rcbp) from the average of the total thermal resistance (Rct) of the specimens.
[0127] The bare plate thermal resistance (Rcbp), [(?°C)(m2)/W], is the resistance to dry heat provided by the surface air layer as measured on the bare plate. Bare plate thermal resistance values are shown in table 4 below.
[0128] The apparent total evaporative resistance (RetA), [(?kPa)(m2)/W], is the total resistance to evaporative heat transfer for a fabric including the surface air layer and liquid barrier (the descriptor term ‘apparent’ is added to account for the fact that heat transfer may have an added condensation component in non-isothermal conditions). Apparent total evaporative resistance (RetA) is given by the following equation:
RetA = [(Ps- Pa)·A/H - (Ts- Ta)·A]/Rct,
where Ps is the water vapor pressure at the surface plate (kPa), Pa is the water vapor pressure in the local environment (kPa), A is the area of the test plate (0.01 m2), H is power input (W), Ts is temperature at the plate surface (35°C), Ta is temperature at the local environment (25°C), and Rct is the total thermal resistance as defined above.
[0129] The apparent intrinsic evaporative resistance (RefA), [([(?kPa)(m2)/W], is the resistance to evaporative heat transfer provided by the fabric alone. The apparent intrinsic evaporative resistance (RefA) is determined by the apparent total evaporative resistance (RetA) minus the average bare plate evaporative resistance (Rebp).
[0130] The bare plate thermal resistance (Rebp), [(?kPa)(m2)/W], is the resistance to evaporative heat transfer provided by the liquid barrier and surface air layer as measured on the bare plate (with liquid barrier attached).
[0131] Total heat loss (Qt), [W/m2], is an indicator of the heat transferred through the fabric material by the combined dry and evaporative heat loss, from a fully sweating test plate surface into the test environment. Total heat loss, measured at a 100% wet skin condition, indicates the highest predicted metabolic activity level that a user may sustain and still maintain body thermal comfort while in a highly stressed state in a test environment. Total heat loss (Qt) is calculated using the following equation:

[0132] The total insulation value (It), [clo], is the thermal resistance measured in units of clo, which indicates the insulating ability of the fabric material. Materials with higher clo values provide more thermal insulation. The clo value includes the insulation provided by the air layer above the fabric and does not subtract it out as with Rcf discussed above. It (clo) values are derived using dry plate test results, from the formula It = Rct*6.45.
[0133] The im value, or permeability index, indicates moisture-heat permeability through the fabric on a scale of 0 (totally impermeable) to 1 (totally permeable) normalized for the permeability of still air (naked skin). This comfort parameter indicates the effect of skin moisture on heat loss as in the case of a sweating skin condition. This value includes the evaporative resistance provided by the air layer above the sample and does not subtract it out as with RefA discussed above. The Im value (permeability index) is calculated, using both dry and sweating plate test results, from the formula Im = 0.060 * (Rct/RetA).
[0134] The average values for Rct, RetA, Rcf, RefA, It, im, and Qt of the Examples A and B are shown in Table 4 below. The average bare plate values are shown in Table 5. Weights and thicknesses for each sample are given in Table 3 above.
[0135] Table 4: Sweating Hot Plate Data
Example Rct RetA Rcf RefA It Im Qt
A 0.080 0.00848 0.012 0.00326 0.518 0.569 710.12
B 0.080 0.00727 0.012 0.00213 0.518 0.654 835.06

[0136] Table 5: Bare Plate Test Data
Rcbp Rebp
Average 0.069 0.005219

[0137] Heat transfer makes it possible to predict the body heat that will flow from the skin surface through the flat woven fabric into the surrounding atmosphere. As illustrated in Table 4 above, example B, which included the present invention yarn configuration, had greater heat loss in humid and sweat conditions and increased ability to transport moistures, e.g., sweat. Table 5 indicates that Evaporative Resistance (RetA) for example A is greater than the Evaporative Resistance (RetA) for example A, indicating that example B allows moisture transfer more quickly to the atmosphere. The total heat loss (Qt) for example B is higher than the total heat loss for example A, indicating example B can transfer heat more quickly to the atmosphere, which indicates the example B fabrics would keep a user cooler.
[0138] The comfort profile also relates thermal insulation properties of flat woven fabrics used to form sheeting products. The thermal insulation properties can be determined in terms of thermal resistance and can be measured accordance with ASTM F 1291 - 16 Standard Method for Measuring the Thermal Insulation of Clothing Using a Heated Manikin, the entirety of the which is incorporated by reference into the present disclosure. Exemplary flat woven fabrics were constructed and included the attributes illustrated in Table 6.
[0139] Table 6: Examples for Thermal and Evaporative Resistance Test
Example C D E
Fiber Content Flat fabric made from 100% Cotton (without soluble fibre) Flat fabric made from present invention yarn AS (with soluble fibre) Flat fabric made from present invention yarn AG (with soluble fibre)
Thread Count 400 400 400
Warp Ne 80 80 80
Weft Ne 80 70 60
EPI 196 196 196
PPI 201 201 201
Weave Design Satin Satin Satin

[0140] Tests for thermal resistance should occur in non-isothermal conditions, such as those shown in Table 7. Prior to testing the manikin was stabilized in the 20°C environment within the chamber. After the bed was made, the test session was started, and the manikin was placed on the mattress/fitted sheet and was covered with the accompanying top-sheet. After which the manikin was left to stabilize for 20 minutes. After the 20-minute mark the conditions of the chamber would be changed from 20°C to 25°C. Once 25°C was reached the manikin was allowed to stabilize at which point the test session was stopped. One repetition was completed for each sheet set, as specified by the above referenced test standard.
[0141] Table 7: Testing Conditions
Thermal Resistance
Air Temperature (°C) 20-25
RH (%) ~60
Air Speed (m/s) 0.2-0.4
Skin Temperature (°C) 35

[0142] Thermal resistance measurements were taken from all sections (Whole Body) as well as the front of manikin (the area completely covered by the test sheets and not in contact with a mattress). Thermal resistance values were converted to units of clo. The measurement of heat transfer is a measure of heat flow from the manikin surface (heated to a skin surface temperature of 35°C) through an ensemble into the test environment and is determined for both simulated dry and wet skin conditions. Heat loss parameters in this context, calculated from thermal transport measurements, include; a) the total thermal resistance (Rct) provided by the manikin, fabric ensemble, and air layers; b) the total evaporative resistance (Ret), [kPa·m2/W], which is the total evaporative resistance provided by the manikin, fabric ensemble, and air layers; c) the intrinsic thermal resistance (Rcl), [°C·m2/W], total thermal resistance provided by the garment ensemble only; d) the intrinsic evaporative resistance, [kPa·m2/W] is the intrinsic evaporative resistance provided by the fabric ensemble only; e) the total insulation value (It), [clo]; f) the Im value, or permeability index; and g) the predicted heat loss potential (Qt), [W/m2], is a predicted level of the total amount of heat that could be transferred from the manikin to the ambient environment for a specified condition. It uses the thermal and evaporative resistance values to calculate predicted levels of evaporative and dry heat transfer components for a specific environmental condition. In this case the specified environment is 25°C, 65% RH. Table 8 provides predicted heat loss values for the “Front Body” test for examples C, D and E. Table 9 provides predicted heat loss values for the “Whole Body” test for examples C, D and E.
[0143] Table 8: Predicted Heat Loss Data for Front Body Manikin
Degrees(°C) Example C Example D Example E
20 49.1 47.7 48.4
20.5 47.3 45.7 47.2
21 46.8 44.4 46.4
21.5 46.7 43.6 46.1
22 46.7 43 45.8
22.5 47 42.3 45.8
23 47 42.3 45.6
23.5 46.8 42.4 45.3
24 46.6 42.1 45
24.5 47.4 42.8 45.3
25 47 43.2 45.7

[0144] Table 9: Predicted Heat Loss Data for Whole Body Manikin
Degrees(°C) Example C Example D Example E
20 48.4 47.5 46.6
20.5 46.6 45.4 45.4
21 46.1 44.1 44.7
21.5 46 43.3 44.4
22 46.1 42.9 44.1
22.5 46.3 42.4 44
23 46.3 42.4 43
23.5 46.4 42.4 43.6
24 46.3 42.2 43.6
24.5 47 42.6 43.3
25 46.7 42.7 44.1

[0145] As shown in tables 8 and 9, “front” and “whole body” data indicate that examples D and E, which include present invention yarn, have lower heat loss values compared to typical flat woven fabrics that do not include the present invention yarn. The data indicates that sheeting products made from examples D and E will tend to keep a user cooler compared to sheeting products made from example C.
[0146] The blowroom units, carding units, combing units, roving units, lapping units, spinning units, ring frame unit, airjet spinning system, open end spinning system, rotor spinning system, Uster Testing machine machine referenced throughout this disclosure are well known in the art and skilled person in the art would know how to employ them in the processes and methods described in this disclosure.
[0147] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
,CLAIMS:WE CLAIM:
1. A method for producing a yarn, comprising the steps of:
subjecting at least one primary fibre in a drawing unit (109) to obtain a sliver of primary fibre;
subjecting at least one soluble fibre in a drawing unit (113) to obtain a sliver of soluble fibre;
blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit (111) to obtain a first blended sliver;
drawing the first blended sliver in a drawing unit (114) along with the sliver of soluble fibre and optionally a combed primary sliver to obtain a second blended sliver; and
spinning a roving of second blended sliver in a yarn spinning unit (116) or spinning the second blended sliver in a yarn spinning unit (120) to obtain the yarn.

2. The method as claimed in claim 1, wherein the combed primary sliver is obtained as follows:
lapping the sliver of primary fibre in a lapping unit (105) to obtain a primary sliver; and
combing the primary sliver in a combing unit (108) to obtain produce the combed primary sliver.

3. The method as claimed in claim 1, wherein the roving of second blended sliver is obtained by passing the second blended sliver through a speed frame roving unit (115).

4. The method as claimed in claim 1, wherein the first blended sliver and/or the second blended sliver is optionally subjected to one or more drawing units along with one or more of the following: sliver of primary fibre, sliver of soluble fibre, and combed primary sliver.

5. A yarn obtained from the method as claimed in claim 1, wherein the yarn comprises a blend of the at least one primary fibre and the at least one soluble fibre, wherein the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre, characterized in that:
(i) a degree of unevenness in the yarn after spinning ranges between 8.5% to 10% and reduces to a range between 7% to 8% after subjecting the yarn to a wet processing step, the degree of unevenness being determined by the Uster Test;
(ii) thin places in the yarn after spinning range between 3500 to 5000 per 1000 meter and reduce to a range between 3000 to 4000 per 1000 meter after the wet processing step;
(iii) thick places in the yarn after spinning range between 2000 to 2200 per 1000 meter and reduce to a range between 2000 to 2100 per 1000 meter after the wet processing step; and
(iv) extra thick places in the yarn after spinning range between 150 to 350 per 1000 meter and reduce to a range between 50 to 100 per 1000 meter after the wet processing step.

6. The yarn as claimed in claim 5, wherein the wet processing step is carried out in presence of one or more chemicals selected from the group consisting of a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer / buffer, alkali, hydrogen peroxide, water, solvent, and levelling agent.

7. The yarn as claimed in claim 5, wherein the at least one primary fibre is selected from the group consisting of a cotton, linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (sustainable or recycled), polylactic acid (PLA), polybutylene terephthalate (PBT), nylon, acrylic, and mixtures thereof.

8. The yarn as claimed in claim 5, wherein the at least one soluble fibre is selected from a polyvinyl alcohol (PVA), wool, silk, co-polymer of polyester, bio-based compostable and biodegradable fibers, bio-based non-compostable and non-biodegradable fibers, non-bio-based compostable and biodegradable fibers, non-bio-based non-compostable and non-biodegradable fibers, and mixtures thereof.

9. A method for producing a fabric, said method comprising the steps of:
subjecting at least one primary fibre in a drawing unit (109) to obtain a sliver of primary fibre;
subjecting at least one soluble fibre in a drawing unit (113) to obtain a sliver of soluble fibre;
blending the sliver of primary fibre with the sliver of soluble fibre in a drawing unit (111) to obtain a first blended sliver;
drawing the first blended sliver in a drawing unit (114) along with the sliver of soluble fibre and optionally a combed primary sliver to obtain a second blended sliver;
spinning a roving of second blended sliver in a yarn spinning unit (116) or spinning the second blended sliver in a yarn spinning unit (120) to obtain the yarn; and
weaving or tufting the yarn to obtain the fabric.

10. The method as claimed in claim 9, wherein prior to weaving or tufting, the yarn is wound into packages, optionally in an autoconer unit (117), and then subjected to a plying unit (118).

11. The method as claimed in claim 9, wherein the fabric is subjected to a wet processing in the presence of one or more chemicals selected from the group consisting of a wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer or a buffer, and levelling agent.

12. The method as claimed in claim 9, wherein the tufting is carried out in a tufting unit, whereby the yarn is stitched or punched on a base material fabric.

13. A fabric made from a yarn as claimed in claim 5, comprising a blend of at least one primary fibre and at least one soluble fibre, wherein the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre, homogeneously distributed with the primary fibre.

14. The fabric as claimed in claim 13, wherein the fabric is selected from the group consisting of a tufted fabric, a terry fabric, and a flat fabric.

15. The fabric as claimed in claim 13, wherein the fabric is used to make a textile product selected from the group consisting of a bedsheet, terry towel, carpet, area-rug, bathrobe, sheeting, and apparel.

16. A fabric made from a yarn as claimed in claim 5, comprising a blend of at least one primary fibre and at least one soluble fibre, wherein the yarn comprises 5 wt.% to 60 wt.% of the at least one soluble fibre, homogeneously distributed with the primary fibre, characterized in that the fabric is selected from the group consisting of tufted fabrics, terry fabrics, and flat fabrics; and the fabric exhibits improved properties of bulkiness, absorbency, thermal insulation, and softness, compared to normal fabric, with wash.