Claims:WE CLAIM:
1. A process for preparing a composite yarn having a spun-like texture; said process comprising:
a. feeding a partially oriented yarn having a first predetermined denier and a fully drawn yarn having a second predetermined denier to a first interlace jet;
b. interlacing at least a portion of the partially oriented yarn and the fully drawn yarn to obtain a partially interlaced yarn;
c. drawing the partially interlaced yarn at a predetermined draw ratio to obtain a drawn yarn; and
d. texturizing the drawn yarn to obtain composite yarn having a spun-like texture.
2. The process as claimed in claim 1, wherein the first predetermined denier is in the range of 80 to 550 D.
3. The process as claimed in claim 1, wherein the second predetermined denier is in the range of 50 to 150 D.
4. The process as claimed in claim 1, wherein the predetermined draw ratio is in the range of 1.1 to 1.4.
5. The process as claimed in claim 1, wherein the step of texturing the drawn yarn comprises following sub-steps:
a. heating the drawn yarn obtained in step (c) in a first heater at a first pre-determined temperature to obtain a heated yarn;
b. cooling the heated yarn in a cooler plate to a second pre-determined temperature to obtain a cooled yarn;
c. twisting the cooled yarn in a belt twister to obtain a twisted yarn; and
d. setting the twisted yarn in a second heater at a third pre-determined temperature to obtain composite yarn having a spun-like texture.
6. The process as claimed in claim 5, wherein the first pre-determined temperature is in the range of 150 to 230 °C.
7. The process as claimed in claim 5, wherein the second pre-determined temperature is in the range of 30 to 35 °C.
8. The process as claimed in claim 5, wherein the third pre-determined temperature is in the range of 110 to 200 °C.
9. The process as claimed in claim 5, wherein the process further comprises the step of interlacing the twisted yarn in a second interlace jet before the step of setting.
10. The process as claimed in claim 1, wherein the process further comprises the step of winding the spun-like textured composite yarn at a predetermined speed such that the winding speed is lower than the drawing speed.
11. The process as claimed in claim 1, wherein the process further comprises the step of oiling the spun like textured composite in an oiler before the step of winding.
Dated this 6th day of November, 2019

MOHAN RAJKUMAR DEWAN
of R.K. DEWAN & COMPANY
IN/PA-25
APPLICANT’S PATENT ATTORNEY

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI
, Description:

FIELD
The present disclosure relates to a process for preparing a composite yarn having a spun-like texture.
DEFINITION
As used in the present disclosure, the following terms 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.
Spun yarn refers to textile yarn, spun from staple-length fiber. It has a softer feel & subdued look.
Spun-like yarn refers to a texturized yarn having softer feel & subdued look like spun yarn.
Texturizing process refers to the process by which synthetic fibers are modified to change their texture i.e., the physical appearance of the fiber.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Textured yarns have many desirable attributes such as increased warmth, greater water absorption capacity, good draping capacity, etc. but these are accompanied by limitations, particularly with respect to bulk, cover and comfort factors. Textured yarns have brighter look, slippery hand which are not liked by all users.
Spun yarns have a particularly desirable characteristic such as softness and when woven into fabrics, the spun yarns have the ability to produce low density, porous, permeable and comfortable materials. Spun yarns exhibit a softer feel & subdued look compared to textured yarns leading to preference by users. However, spun yarns have certain limitations such as difficulty in dyeability, low yarn strength, prone to shrinking and stretching, dries slowly, and isn’t wrinkle resistant.
It is therefore desirable to manufacture a yarn having spun-like texture. Many attempts have been made to manufacture a yarn having spun-like texture, but various limitations in the resulting products have prevented the efforts for manufacturing a yarn having spun-like texture.
There is, therefore, felt a need to develop a process for preparing a composite yarn having spun-like texture.
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 ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a process for preparation of a composite yarn having spun-like texture.
Yet another object of the present disclosure is to provide a simple and economical process for preparation of the composite yarn having spun-like texture.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a process for preparing a composite yarn having spun-like texture.
Initially, a partially oriented yarn having a first predetermined denier and a fully drawn yarn having a second predetermined denier is fed to a first interlace jet. At least the portions of the partially oriented yarn and the fully drawn yarn are interlaced to obtain a partially interlaced yarn. The partially interlaced yarn is drawn at a predetermined draw ratio to obtain a drawn yarn. The drawn yarn is further texturized to obtain the composite yarn having spun-like texture.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The texturized yarn of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic representation of the process for preparing a composite yarn having spun-like texture.
Reference Numerals:
1 POY bundle
2 FDY/DDLS bundle
3 Creel guide attachment
4 Pre-Interlace jet
5 Input roller
6 Primary heater
7 Cooling plate
8 Belt false-twister
9 OLT sensor
10 Intermediate roller
11 Interlace jet
12 Secondary heater
13 Output roller
14 Oiler
15 Winder

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Spun yarns exhibit a softer feel & subdued look as compared to textured yarns leading to preference by users. However, spun yarns have certain limitations such as difficult dyeability, low yarn strength, prone to shrinking and stretching, dries slowly, and is not wrinkle resistant. It is desirable to manufacture a composite yarn having spun-like texture.
The present disclosure therefore provides a process for preparing a composite yarn having a spun-like texture. The process is described in detail herein below.
Initially, a partially oriented yarn having a first predetermined denier and a fully drawn yarn having a second predetermined denier are fed to a first interlace jet. At least the portions of the partially oriented yarn and the fully drawn yarn are interlaced to obtain at least a partially interlaced yarn. The partially interlaced yarn is drawn at a predetermined draw ratio to obtain a drawn yarn. The drawn yarn is further texturized to obtain the composite yarn having spun-like texture. The so obtained composite yarn is further winded on a winder.
In accordance with the embodiments of the present disclosure, the first predetermined denier is in the range of 80 to 550 D. Preferably, the first predetermined denier is in the range of 100 to 250 D.
In accordance with the embodiments of the present disclosure, the second predetermined denier is in the range of 50 to 150 D. Preferably, the second predetermined denier is in the range of 70 to 140 D.
The process by which the yarn or fiber is elongated by passing it through a series of pair of rollers, each pair moving faster than the previous one is called drawing. The drawing of the yarns is carried out to reduce creepe properties, to increase orientation and crystallinity, and to remove brittleness from the yarn. Typically, the ratio of speed of the front roller to the back roller is called drawing ratio. In accordance with the present disclosure, the draw ratio is in the range of 1.1 to 1.4. The draw ratio is maintained at lower value with the aim of obtaining softer feel to the textured yarn.
In accordance with the embodiments of the present disclosure, the winding speed of the composite yarn is lower than the drawing speed, to maintain lower tension in the yarn.
The texturing of the drawn yarn, is carried out by sequentially heating, cooling, twisting and setting the drawn yarn.
The drawn yarn is heated in a first heater maintained at a first pre-determined temperature to obtain a heated yarn, followed by cooling the heated yarn in a cooler plate to a second pre-determined temperature to obtain a cooled yarn.
The cooled yarn is twisted typically in a belt twister to obtain a twisted yarn.
The twisted yarn is subjected to setting in a second heater maintained at a third pre-determined temperature to obtain composite yarn having a spun-like texture.
In accordance with the embodiments of the present disclosure, the first pre-determined temperature is in the range of 150 to 230 °C, the second pre-determined temperature is in the range of 30 to 35 °C, and the third pre-determined temperature is in the range of 110 to 250 °C.
The twisted yarn so obtained from the belt twister is further subjected to the step of interlacing in a second interlace jet. The step of intermingling or alias interlacing mixes multifilament yarns along with knots and open sections alternately throughout the length of the yarns. This technique enhances the strength of yarn.
The composite yarn having spun-like texture is further subjected to oiling in an oiler before winding it on a winder. In accordance with the present disclosure, the oil used for oiling of the composite yarn is a vegetable oil. The composite yarns develop a static charge, which creates difficulties in the downstream processing. To obviate this problem, the composite yarn is subjected to step of oiling, which renders formation of the static charge.
The present disclosure is further illustrated with the help of the figure.
Figure-1 discloses a schematic representation of the process for preparing a composite yarn having a spun-like texture.
Typically, the process for preparing a composite yarn comprises feeding the POY (Partially oriented yarn) from a first spool/bobbin (1) and FDY (Fully Drawn yarn) from a second spool/bobbin (2) to a pre-interlace jet (4) via a creel guide attachment (3). The interlaced yarn obtained from the pre-interlace jet (4) is drawn through a first roller (5) to obtain a drawn yarn. The drawn yarn is then texturized by sequentially heating the drawn yarn in a first heater (6) followed by cooling in a cooler plate (7). The cooled yarn is twisted in a belt twister (8) and then passed through a OLT (optical line terminal) sensor (9), wherein the tension in the yarn is monitored. The twisted yarn is passed through an intermediate roller (10) and subjected to setting in a secondary heater (12) to obtain the composite yarn having a spun like texture. The composite yarn is further passed through output roller (13) and then winded on a winder (15).
The process involves the step of interlacing the twisted yarn in a second interlace jet (11) before the step of setting.
The process involves the step of passing the composite yarn though an oiler (14) before the step of winding.
The present disclosure provides a modified process for texturing the yarns to obtain composite yarn having a spun-like texture. The process involves pre-interlacing of the POY and FDY to obtain the interlaced yarn. The step of pre-interlacing of the yarn helps in obtaining softer feel to the textured yarns.
The interlaced yarn is further subjected to drawing and texturing process. The texturing process involves sequential heating in a first heater, twisting in a belt twister and finally setting in a second heater. In accordance with the present disclosure, the temperature of the second heater is lower than the temperature of the first heater, which attributes softness in the yarn.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
General Process:
A partially oriented yarn having a first predetermined denier and a fully drawn yarn having a second predetermined denier were fed to a first interlace jet to obtain a partially interlaced yarn.
The partially interlaced yarn was then drawn at a predetermined draw ratio to obtain a drawn yarn.
The drawn yarn was texturized by heating the drawn yarn in a first heater at a first pre-determined temperature to obtain a heated yarn followed by cooling the heated yarn in a cooler plate to a second pre-determined temperature to obtain a cooled yarn and then subjecting the cooled yarn in a belt twister to obtain a twisted yarn. The twisted yarn was then subjected to setting in a second heater at a third pre-determined temperature to obtain composite yarn having a spun-like texture.
The so obtained composite yarn was passed through oiler for the purpose of oiling the yarn, thereby rendering formation of static charge. The oiled composite yarn was winded on a winder at a speed lower than the drawing speed.
Experiment 1- 8: Preparation of the composite yarn
The experiments 1-8 were carried out by following the process as disclosed herein above, with variable process parameters.
The process parameters used and the results obtained are summarized in Table 1 herein below:
Table 1: The parameters used in the process for obtaining the composite yarn and the characteristic values of the composite yarn.
Experiment No. 1 2 3 4 5 6 7 8
Hardware Belt False Twist Texturing Machine Belt False Twist Texturing Machine Belt False Twist Texturing Machine Belt False Twist Texturing Machine Belt False Twist Texturing Machine Belt False Twist Texturing Machine False Twist Texturing Machine with ACY Attachment
(Comparative Example) Spindle False Twist Texturing Machine
(Comparative example)
Materials used
POY 80D/72F SD POY 80D/72F SD POY 160D/144F SD POY 245D / 288F SD POY 390D /72F SD POY 700D / 96 F SD POY 80D/72F SD POY 195 D/72
FDY 50/24F DDLS 75D/48F BRT DDLS 75D/48F BRT DDLS 150D / 48F SD DDLS 150D / 48F SD DDLS 300D / 96F SD DDLS 75D/48F BRT DDLS + 40 Spandex -
Process parameters
Drawing Speed 300 300 350 300 425 430 300 775
D.R 1.28 1.29 1.34 1.35 1.35 1.32 1.305 1.79
Velocity Ratio 1.68 1.65 1.8 1.7 1.65 1.85 1.69 1.44
Twisting Belt Twisting Belt Twisting Belt Twisting Belt Twisting Belt Twisting Belt Twisting False Twist Texturing Spindle twisting
Type of Jet P-213 P-213 P-213 P-312 P-312 P-412 P-312 P-143
Air Pressure 2.8 3.0 3.2 3.0 3.8 3.8 3.5 4
First Temp 150 175 177 195 210 220 180 200
Second Temp. 30 32 30 35 31 30 25 32
Third Temp 110 120 125 130 160 180 160 210
Characteristics of the product
Product
Obtained 100/96 Sapan 135/120 Sapan 230/178 Sapan 350/336 Sapan 450/120 Sapan 800/192 Sapan 140/121 comfort sapan 120/72 HIM
Denier (D) 100.1 132 220.3 327.2 448.1 798.8 140.3 125.5
Elon % 35.1 34.5 32.2 33.4 34.0 34.5 22 25.5
Ten (gpd ) 2.6 2.7 2.6 2.7 2.4 2.3 2.5 3.5
CC % 9.5 11 6 6.8 8.4 6.8 62.1 9.7
SH % 2.8 2.2 2.4 2.4 3.2 3.5 2.5 1.5
OPU % 3.6 3.5 4 3.4 3.5 3.8 3.3 4.4
Nips/mtr 106 108 100 88 69 60 9.5 152
Ret 5% 100 100 100 100 100 100 _ 100
Ret 10% 100 100 100 100 100 100 _ 100
Dyeing Uniform Uniform Uniform Uniform Uniform Uniform Uniform Uniform
*Ten: tenacity, CC: crimp contraction, SH: hot shrinkage, OPU: oil pick up, ACY: air covered yarn, DDLS: deep dye low shrinkage, SD: semi dull, BRT: bright.
As observed in Table 1, the composite yarns obtained in experiments 1-6 have higher elongation % as compared to the yarns obtained in comparative experiments 7-8, which proves that the composite yarns obtained by the process of the present disclosure have a spun-like texture. The lower machine speed, lower draw ratio and pre-interlace process leads to the formation of spun-like texture in the composite yarn.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a process for preparing a composite yarn, which:
? provides the composite yarn having spun-like texture; and
? is simple and economical.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples 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 the embodiments herein.
The foregoing description of the specific embodiments 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.
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 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 components and component parts of the preferred embodiments, it will be appreciated that many embodiments 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 changes in the preferred embodiment as well as other embodiments of the disclosure 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.