Description:
FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)

1. Title of the invention – A POLYPROPYLENE YARN AND METHOD OF PREPARATION THEREOF

2. Applicant(s)

(a) NAME: MMP FILTRATION PVT. LTD.
(b) NATIONALITY: INDIAN
(c) ADDRESS: C3 / 602, ANUSHRUTI TOWERS, SG HIGHWAY, THALTEJ, AHMEDABAD – 380059 INDIA

3. PREAMBLE TO THE DESCRIPTION

The following specification particularly describes the invention and the manner in which it is to be performed.

 
A POLYPROPYLENE YARN AND METHOD OF
PREPARATION THEREOF

FIELD OF THE INVENTION

The present invention is related to a polypropylene yarn and method of preparation thereof. More particularly, a polypropylene yarn that can filter water without producing foam and the method of preparation of the polypropylene yarn.

BACKGROUND OF THE INVENTION

Water filtration is essential for ensuring clean and safe drinking water. Polypropylene (PP) yarns have gained significant attention in water filtration applications due to their lightweight, chemical resistance, and ability to form nonwoven and woven filter media. These yarns are commonly produced through an extrusion process where specific chemicals, such as stabilizers, lubricants, and processing aids, are added to improve process ability and mechanical properties. However, these chemical additives pose potential risks to human health when they leach into water during filtration.

Many of these additives, including antioxidants, slip agents, and antistatic compounds, contain substances that may be harmful when ingested over prolonged exposure. Residual processing chemicals can dissolve into the water, leading to potential contamination. Thus, there is an urgent need to develop polypropylene-based filtration yarns that do not rely on harmful chemical additives during the extrusion process. Conventional yarn manufacturing technologies, such as the open-end spinning machine, are commonly used for producing coarse, high-strength yarns from staple fibres.

One such invention is disclosed in Patent “CN101718015A” titled - Production method of rotor-spinning polyester-viscose blended knitting yarn. The invention discloses, the invention describes a method for producing rotor-spinning polyester-viscose blended knitting yarn. The process begins by pre-moistening polyester fibres for 12-36 hours, followed by spraying an antistatic agent and a softening agent onto the fibres. The polyester fibres are then prepared into drawings A through bale arranging and blowing-carding, while viscose fibres are prepared into drawings B. Next, the drawings A and B are mixed to create drawings C, and drawings C are blended with drawings B multiple times to adjust the viscose fibre ratio, resulting in drawings D. Finally, the drawings D are processed into knitting yarn using rotor-spinning equipment. This method solves the issues of static electricity and low resurgence in polyester fibres by incorporating an antistatic agent, while also enhancing the hand-feel of the yarn with the addition of a softening age.

The conventional technology has a fundamental limitation when it comes to manufacturing chemical-free polypropylene yarns for filtration. The inherent high-friction spinning process generates excessive heat and mechanical stress on the fibres, making it impractical to produce yarns without the aid of chemical stabilizers and lubricants. Without these additives, polypropylene fibres suffer from severe wear, breakage, and degradation, rendering the process inefficient and unviable. Further foam generate at the time of water filtration may significant decrease the flow of water and that in turn increases the concentration of the chemicals in the water.

To overcome all these drawbacks of the prior arts, the inventors of the present invention came up with a polypropylene yarn and method of preparation thereof.

OBJECT OF THE INVENTION

The principle object of present invention is to overcome the drawbacks and limitations associated with prior technology by a polypropylene yarn and method of preparation thereof.

Another object of the present invention is to provide a polypropylene yarn that filters water without producing foam.

Yet another object of the present invention is to provide a polypropylene yarn that is made without the use of antistatic reagent.

Yet another object of the present invention is to provide a polypropylene yarn that is made without the use of lubricants.

Yet another object of the present invention is to provide a method of preparation for a polypropylene yarn made without the use of antistatic reagent.

Yet another object of the present invention is to provide a method of preparation for a polypropylene yarn made without the use of lubricants.

Yet another object of the present invention is to provide a method of preparation for a polypropylene yarn that has good strength despite not using antistatic reagent and lubricants.

Yet another object of the present invention is to provide a method of preparation for a polypropylene yarn that reduces the friction in the preparation process to maintain the quality of the finished yarn.

Yet another object of the present invention is to provide a polypropylene yarn with better water filtration capabilities.

SUMMARY OF THE INVENTION

The main aspect of the present invention is a process for producing polypropylene yarn, comprising the steps of:
a. collecting bales of fibre, said fibre composed of polypropylene, as the raw material;
b. opening the bales for atmospheric condition for a predetermined period after step a;
c. scattering and mixing of the fibres after step b;
d. spraying the fibres with demineralized water with predetermined percentage on weight of fibre (OWF) after step c;
e. conditioning in atmosphere for a predetermined period after step d;
f. beating of the fibres in blowroom with predetermined RPM of the cylindrical beaters after step e;
g. feeding of the fibres to a carding machine via pneumatic line system to form sliver after step f;
h. conditioning of the sliver for a predetermined period after step g;
i. feeding plurality of sliver in an friction spinning machine to produce polypropylene yarn after step h.
j. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step i.
k. packing of the polypropylene yarn.

Another aspect of the present invention is to provide a polypropylene yarn that can filter water without producing foam.

Another aspect of the present invention is to provide a polypropylene yarn that is nontoxic.

Another aspect of the present invention is to provide a method of preparation for polypropylene yarn that can manage the friction on the yarn in production to maintain the quality of the finished yarn.

Another aspect of the present invention is to provide a method of preparation for polypropylene that maintains structural integrity and strength.

BRIEF DESCRIPTION OF DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

Fig. 1 is a diagram of carding machine.

Fig. 2 is a diagram of friction spinning machine.

DETAILED DESCRIPTION OF INVENTION

The present invention overcomes the aforesaid drawbacks of the above, and other objects, features and advantages of the present invention will now be described in greater detail. Also, the following description includes various specific details and are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that: without departing from the scope of the present disclosure and its various embodiments there may be any number of changes and modifications described herein.

It must also be noted that as used herein and in the appended claims, the singular forms "a", "an," and "the" include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems and methods are now described.

As per main embodiment of the present invention, a process for producing polypropylene yarn, comprising the steps of:
a. collecting bales of fibre, said fibre composed of polypropylene, as the raw material;
b. opening the bales for atmospheric condition for a predetermined period after step a;
c. scattering and mixing of the fibres after step b;
d. spraying the fibres with demineralized water with predetermined percentage on weight of fibre (OWF) after step c;
e. conditioning in atmosphere for a predetermined period after step d;
f. beating of the fibres in blowroom with predetermined RPM of the cylindrical beaters after step e;
g. feeding of the fibres to a carding machine via pneumatic line system to form sliver after step f;
h. conditioning of the sliver for a predetermined period after step g;
i. feeding plurality of sliver in an friction spinning machine to produce polypropylene yarn after step h.
j. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step i.
k. packing of the polypropylene yarn.

As per detailed embodiment of the present invention, the atmospheric condition of the opened bales for a predetermined period depends on the geographic location and weather conditions. The predetermined period can range from 14 hours to 34 hours and the preferred range is from 18 hours to 30 hours.

As per detailed embodiment of the present invention, the fibres are scatter and mixed within various opened bales which may or may not be of same batch.

As per detailed embodiment of the present invention, the predetermined percentage of sprayed demineralized water can range from 3% to 6% on the weight of fibre (owf) and the preferred range is from 3.5 % to 5.5%.

As per detailed embodiment of the present invention, the conditioning in atmosphere for a predetermined period depends on the geographic location and weather conditions. The predetermined period can range from 26 hours to 46 hours and the preferred range is from 30 hours to 40 hours.

As per detailed embodiment of the present invention, the beating of the fibres in blowroom with predetermined RPM. The predetermined RPM of the cylindrical beaters can range from 800 to 1000 and the preferred RPM range is 850 to 950.

As per detailed embodiment of the present invention, the conditioning of the sliver for a predetermined period depends on the geographic location and weather conditions. The predetermined period can range from 14 hours to 34 hours and the preferred range is from 18 hours to 30 hours.

As per another embodiment of the present invention, the carding machine (200) comprising the steps of:
a. feeding of the fibres A (101) in between a plurality of feed rolls A via the pneumatic line system;
b. rotating of the feed rolls A (201) and feeding the fibres A (101) on to the beater (202) after step a;
c. beating of the fibres A (101) through rotation of the beater (202) after step b;
d. collecting fibres A (101) in a chute (203) after step c;
e. feeding of the fibres A (101) on to a feed plate (205) from chute (203) through rotation of at least 3 feed rolls B (204) after step d;
f. feeding of the fibres A (101) on to a licker-in (207) through rotation of a feed roll C (206) after step e;
g. feeding of the fibres A (101) on to a cylinder (208) through rotation of the licker-in (207) after step f;
h. pressing of the fibres A (101) in between the cylinder (208) and a moving flats (209) through rotation of both after step g;
i. removing of the fibres A (101) from the cylinder (208) through rotation of a doffer (210) after step h;
j. pressing of fibres A (101) between a plurality of crush rolls (211) after step i;
k. forming of sliver (102) after step j;
l. collecting of sliver (102) in a can (213) through a plurality of guiding rolls (212) after step k.

As per detailed embodiment of the present invention, the doffer (210) being capable of reducing the output from 160 meters per minute to 130 meters per minute.

As per another embodiment of the present invention, friction spinning machine (300) comprising the steps of:
a. feeding and squeezing of the sliver (102) in a plurality of nylon rollers A (301);
b. feeding of the sliver (102) on to a plurality of nylon rollers B (302) after step a;
c. feeding of the sliver (102) on to an opening roller (303) after step b;
d. opening of the sliver (102) into fibre (103) through rotation of the opening roller (303) at predetermined RPM after step c;
e. blowing of the fibre strands into a plurality of perforated drums (304) via air jet (305) after step d;
f. spinning of fibre (103) strands into yarn through rotation of perforated drums (304) in a predetermined direction;
g. removal of air after step f;
h. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step g;
i. packing of the polypropylene yarn.

As per detailed embodiment of the present invention, the disc type tension assembly being capable of reducing the hairiness of the polypropylene yarn by producing tension in the polypropylene yarn.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred RPM range of the beaters (202) is 800 – 1000 and the more preferred range is 850 – 950.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred thickness range of the feed plate (205) is 30 – 38 thou and more preferred range is 32 – 36 thou.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred RPM range of the licker-in (207) is 900 – 1000 and more preferred range is 925 – 975.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred distance range between the moving flats (209) and cylinder (208) is 34 – 28 thou and more preferred range is 33 – 29 thou.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred RPM range of the cylinder (208) is 475 – 575 and the more preferred range is 500 – 550.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred RPM range of the doffer (210) is 110 – 150 and the more preferred range is 120 – 140.

As per another embodiment of the present invention, the process for producing polypropylene yarn, wherein the preferred range of sliver hank is 0.080s – 0.098s Ne and the more preferred range is 0.085s – 0.095s Ne.

As per another embodiment of the present invention, the process for producing polypropylene yarn wherein the preferred RPM range of the opening roller (303) is 650 – 1000 and the more preferred range is 700 – 950.

As per another embodiment of the present invention, a polypropylene yarn comprising; fibres with organic antistatic oil, demineralized water, wherein the polypropylene yarn being capable of filtering water without producing foam.

All the embodiments of the present invention further explained through drawings for the better understanding of the invention.

Fig. 1 of the present invention illustrates the carding machine (200) processes fibres A (101) through a series of steps, beginning with feeding fibres A (101) into feed rolls A (201) and then beating and conditioning them through rotation and mechanical actions of the beater (202). The fibres A (101) are then transferred through various stages, including a feed plate (205), licker-in (207), and cylinder (208), where they are pressed and removed. After being pressed between crush rolls (211), the fibres A (101) form a sliver (102), which is collected in a can (213) via guiding rolls (212). The process comprising the steps of:
a. feeding of the fibres A (101) in between a plurality of feed rolls A via the pneumatic line system;
b. rotating of the feed rolls A (201) and feeding the fibres A (101) on to the beater (202) after step a;
c. beating of the fibres A (101) through rotation of the beater (202) after step b;
d. collecting fibres A (101) in a chute (203) after step c;
e. feeding of the fibres A (101) on to a feed plate (205) from chute (203) through rotation of at least 3 feed rolls B (204) after step d;
f. feeding of the fibres A (101) on to a licker-in (207) through rotation of a feed roll C (206) after step e;
g. feeding of the fibres A (101) on to a cylinder (208) through rotation of the licker-in (207) after step f;
h. pressing of the fibres A (101) in between the cylinder (208) and a moving flats (209) through rotation of both after step g;
i. removing of the fibres A (101) from the cylinder (208) through rotation of a doffer (210) after step h;
j. pressing of fibres A (101) between a plurality of crush rolls (211) after step i;
k. forming of sliver (102) after step j;
l. collecting of sliver (102) in a can (213) through a plurality of guiding rolls (212) after step k.

Fig. 2 of the present invention illustrates the friction spinning machine (300) processes sliver (102) by feeding and squeezing it through nylon rollers A (301) and B (302), then opening the sliver (102) into fibres (103) using an opening roller (303). The fibre strands are blown into perforated drums (304), where they are spun into yarn, with air removed and hairiness reduced through a disc-type tension assembly. Finally, the polypropylene yarn is packed for further use. The process comprising the steps of:
a. feeding and squeezing of the sliver (102) in a plurality of nylon rollers A (301);
b. feeding of the sliver (102) on to a plurality of nylon rollers B (302) after step a;
c. feeding of the sliver (102) on to an opening roller (303) after step b;
d. opening of the sliver (102) into fibre (103) through rotation of the opening roller (303) at predetermined RPM after step c;
e. blowing of the fibre strands into a plurality of perforated drums (304) via air jet (305) after step d;
f. spinning of fibre (103) strands into yarn through rotation of perforated drums (304) in a predetermined direction;
g. removal of air after step f;
h. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step g;
i. packing of the polypropylene yarn.

The present invention was experimented and illustrated more in details in the following example. The example describes and demonstrates embodiments within the scope of the present invention. This example was given solely for the purpose of illustration and is not to be construed as limitations of the present invention, as many variations thereof are possible without departing from spirit.

Example 1: The polypropylene yarn made from the process disclosed in present invention. The Sr. No. 1 in the below table is the conventional polypropylene yarn and the Sr. No. 2 in the below table is the non-foaming polypropylene yarn i.e. the present invention. The polypropylene yarn demonstrated a breaking strength of 14.19 g as opposed to 14.67 g of the conventional polypropylene yarn without the risk of consummation of chemical additives that may have been used in the process of making conventional polypropylene yarn. Further the single fibre strength as per the ASTM D 3822-07 (2014) standard, the polypropylene yarn demonstrated an breaking extension of 88.91 % and calculated tenacity of 4.53 (g/d) as opposed to breaking extension of 15.00 % and calculated tenacity of 6.38 (g/d) for the conventional polypropylene yarn.

Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the illustrative examples, make and utilize the present invention and practice the claimed methods. It should be understood that the foregoing discussion and examples merely present a detailed description of certain preferred embodiments. It will be apparent to those of ordinary skill in the art that various modifications and equivalents can be made without departing from the scope of the invention.

REFERENCE NUMERALS
Fibers A (101)
Sliver (102)
Fibers B (103)
Carding Machine (200)
Feed rolls A (201)
Beater (202)
Chute (203)
Feed rolls B (204)
Feed plate (205)
Feed roll C (206)
Licker-in (207)
Cylinder (208)
Moving flats (209)
Doffer (210)
Crush rolls (211)
Guiding rolls (212)
Friction spinning machine (300)
Nylon rollers A (301)
Nylon rollers B (302)
Opening roller (303)
Perforated drums (304)
Air jet (305)
, Claims:CLAIMS
We Claim,
1. A process for producing polypropylene yarn, comprising the steps of:
a. collecting bales of fibre, said fibre composed of polypropylene, as the raw material;
b. opening the bales for atmospheric condition for a predetermined period after step a;
c. scattering and mixing of the fibres after step b;
d. spraying the fibres with demineralized water with predetermined percentage on the weight of fibre (owf) after step c;
e. conditioning in atmosphere for a predetermined period after step d;
f. beating of the fibres in blowroom with predetermined RPM of the cylindrical beaters after step e;
g. feeding of the fibres to a carding machine via pneumatic line system to form sliver after step f;
h. conditioning of the sliver for a predetermined period after step g;
i. feeding plurality of sliver in an friction spinning machine to produce polypropylene yarn after step h.
j. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step i.
k. packing of the polypropylene yarn.

2. The process for producing polypropylene yarn as claimed in claim 1, wherein the carding machine (200) comprising the steps of:
a. feeding of the fibres A (101) in between a plurality of feed rolls A via the pneumatic line system;
b. rotating of the feed rolls A (201) and feeding the fibres A (101) on to the beater (202) after step a;
c. beating of the fibres A (101) through rotation of the beater (202) after step b;
d. collecting fibres A (101) in a chute (203) after step c;
e. feeding of the fibres A (101) on to a feed plate (205) from chute (203) through rotation of at least 3 feed rolls B (204) after step d;
f. feeding of the fibres A (101) on to a licker-in (207) through rotation of a feed roll C (206) after step e;
g. feeding of the fibres A (101) on to a cylinder (208) through rotation of the licker-in (207) after step f;
h. pressing of the fibres A (101) in between the cylinder (208) and a moving flats (209) through rotation of both after step g;
i. removing of the fibres A (101) from the cylinder (208) through rotation of a doffer (210) after step h;
j. pressing of fibres A (101) between a plurality of crush rolls (211) after step i;
k. forming of sliver (102) after step j;
l. collecting of sliver (102) in a can (213) through a plurality of guiding rolls (212) after step k.

3. The process for producing polypropylene yarn as claimed in claim 1, wherein the friction spinning machine (300) comprising the steps of:
a. feeding and squeezing of the sliver (102) in a plurality of nylon rollers A (301);
b. feeding of the sliver (102) on to a plurality of nylon rollers B (302) after step a;
c. feeding of the sliver (102) on to an opening roller (303) after step b;
d. opening of the sliver (102) into fibre (103) through rotation of the opening roller (303) at predetermined RPM after step c;
e. blowing of the fibre strands into a plurality of perforated drums (304) via air jet (305) after step d;
f. spinning of fibre (103) strands into yarn through rotation of perforated drums (304) in a predetermined direction;
g. removal of air after step f;
h. reducing the hairiness of the polypropylene yarn by passing through a disc type tension assembly after step g;
i. packing of the polypropylene yarn.
4. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred RPM range of the beaters (202) is 800 – 1000 and the more preferred range is 850 – 950.
5. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred thickness range of the feed plate (205) is 30 – 38 thou and more preferred range is 32 – 36 thou.
6. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred RPM range of the licker-in (207) is 900 – 1000 and more preferred range is 925 – 975.
7. The process for producing The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred distance range between the moving flats (209) and cylinder (208) is 34 – 28 thou and more preferred range is 33 – 29 thou.
8. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred RPM range of the cylinder (208) is 475 – 575 and the more preferred range is 500 – 550.
9. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred RPM range of the doffer (210) is 110 – 150 and the more preferred range is 120 – 140.
10. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred range of sliver hank is 0.080s – 0.098s Ne and the more preferred range is 0.085s – 0.095s Ne.
11. The process for producing polypropylene yarn as claimed in claim 1, wherein the preferred RPM range of the opening roller (303) is 650 – 1000 and the more preferred range is 700 – 950.
12. A polypropylene yarn comprising; fibres with organic antistatic oil, demineralized water;
wherein
the polypropylene yarn being capable of filtering water without producing foam.
Dated this 17th March 2025