US20160160406A1 - Production of high cotton number or low denier core spun yarn for weaving of reactive fabric and enhanced bedding - Google Patents

Abstract

A method of producing a core spun yarn is disclosed. A oriented polyester yarn is drawn through a primary heater and exposed to a cooling plate. The oriented polyester yarn is drawn through a friction twisting unit. A spandex core is drawn from a spandex bobbin to become associated with the oriented polyester yarn. Both the spandex core and the oriented polyester yarn are drawn through an intermingling jet, which texturizes the oriented polyester yarn using a hot air punching technique. The oriented polyester yarn is twisted around the spandex core using he intermingling jet and/or the friction twisting unit. The oriented polyester yarn and the spandex core are drawn through a NFR roller and then heated to form the core spun yarn.

Description

CLAIM OF PRIORITY
• This application is a conversion application of and claims priority to the U.S. Provisional Application No. 62/004,887 titled PRODUCTION OF HIGH COTTON NUMBER OR LOW DENIER CORE SPUN YARN FOR WEAVING OF REACTIVE FABRIC AND ENHANCED BEDDING filed on May 29, 2014.
FIELD OF TECHNOLOGY
• This disclosure relates generally to textiles and, more particularly, to a method, an article of manufacture, device and/or a system of production of high cotton number or low denier core spun yarn for weaving of reactive fabric and enhanced bedding.
BACKGROUND
• The comfort of a woven textile against the human skin may be related and/or directly proportional to a thread count. Use of the coarse diameter yarn may lead to a low “thread count” in the woven textile. In contrast, using relatively fine yarns yield a high thread count. A thread count of a textile may be calculated by counting the total weft yarns and warp yarns along two adjacent edges of a square of the woven textile that is one-inch by one-inch. A high thread count may be a commonly recognized indication of the quality of a woven textile, and may also be a measure that consumers associate with tactile satisfaction and opulence.
• A core spun yarn that is comprised of a core filament and a sheath may be used in a production of a woven textile to create a new yarn and/or a fabric that has some characteristics of a material of the core filament and some characteristics of a material of the sheath. For example, a core spun yarn comprising a spandex core and a cotton sheath may have an ability to stretch like a spandex polymer, but still retain a set of favorable characteristics of cotton such as a pleasant feeling to human skin and/or an ability resist a sticky sensation. Core spun yarn may also be referred to a “polycore” yarn, and may be created by twisting a set of staple fibers (also known as a roving) and/or a synthetic yarn (e.g., a polyester yarn) around a central filament core that may be made of a synthetic polymer (e.g., polyester, spandex).
• Core spun yarns may be used in the production of some woven apparel items, but may not have yet been adapted to the production of bedding fabrics or certain types of fine apparel. When the core filament is reduced in diameter in order to construct a corresponding core spun yarn of reduced diameter, the core filament may break during the process by which the sheath is added to the core filament. A smaller diameter instance of the core filament may also break when fed into a loom apparatus to weave the woven textile. Therefore, use of core spun yarn may be limited to applications that tolerate a low thread count, which may prevent imparting the beneficial characteristics of core spun yarns to a set of woven textiles that require a relatively high thread count to be considered usable, saleable, and/or desirable.
SUMMARY
• Disclosed are a method, an article of manufacture, device and/or a system of production of high cotton number or low denier core spun yarn for weaving of reactive fabric and enhanced bedding.
• In one aspect, a method of producing a core spun yarn includes drawing a partially oriented yarn from a polyester supply package through a primary input roller to form an oriented polyester yarn, and drawing the oriented polyester yarn through a secondary input roller. The method further includes drawing the oriented polyester yarn through a primary heater, exposing the oriented polyester yarn to a cooling plate, and drawing the oriented polyester yarn through a friction twisting unit using an intermediate roller. The method also includes drawing a spandex core from a spandex bobbin to become associated with the oriented polyester yarn at a supporting guide located between the friction twisting unit and the intermediate roller.
• The method includes drawing both the spandex core and the oriented polyester yarn through an intermingling jet, and texturizing the oriented polyester yarn using the intermingling jet using a hot air punching technique. Also included is twisting the oriented polyester yarn around the spandex core using the intermingling jet and the friction twisting unit, as well as drawing the oriented polyester yarn and the spandex core through a NFR roller after the intermingling jet. Finally, the method includes heating the oriented polyester yarn and the spandex core using a secondary heater to form the core spun yarn.
• The primary heater and the secondary heater may be set to a temperature between 50° C. and 200° C. Also, the cooling plate may be set to a temperature between 0° C. and 40° C. The intermingling jet may apply a uniform air pressure to the oriented polyester yarn to provide a counter-twist opposing the friction twisting unit. Additionally, the friction twisting unit may manipulate the oriented polyester yarn such that the oriented polyester yarn gains a texture and/or a weaving stability. Also, the manipulation may include a twisting and/or a detwisting.
• The method may include fixing a torsion of the oriented polyester yarn by translating a twist imparted by the friction twisting unit through the oriented polyester yarn back to the primary heater. The secondary input roller may be a twist-stopper preventing the twist from propagating to the polyester supply package. The spandex core may have a denier of 20 to 300.
• In another aspect, a method of producing a core spun yarn includes drawing a roving thread from a roving bobbin through a roving guide, an aft drafting roller, and a mid drafting roller to a front drafting roller. The method further includes drawing a spandex core from a spandex bobbin using a guide roller, associating the roving thread and the spandex core by drawing the roving thread and the spandex core in an approximately parallel fashion through the front drafting roller, and drawing the roving thread and the spandex core through a lappet hook and an anti-ballooning guide. Finally, the method includes winding the roving thread and the spandex core on a ring-frame bobbin including a ring traveler attached to a rotatable ring. A circular motion of the ring traveler around the ring-frame bobbin causes the roving thread to twist around the spandex core, forming the core spun yarn. The roving thread may include cotton staple fibers and/or polyester staple fibers.
• In yet another aspect, a woven textile fabric includes a warp yarn and a weft yarn. The weft yarn is a core spun yarn having a spandex core, and the woven textile fabric is a sateen weave or a plain weave. The woven textile fabric may assume a native state in the absence of external strain, and may assume a first distributed state when experiencing a first strain. Furthermore, the woven textile fabric may assume a second distributed state when experiencing a second strain. The first distributed state may include a slight stretch of the weft yarn which inhibits wrinkles while inhibiting airflow through the woven textile fabric. The second distributed state may include a further stretching of the weft yarn which may permit an enhanced airflow through the woven textile fabric.
• The warp yarn may be 100% cotton and have a 60 Ne count, while the core spun yarn may be a roving-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier from 20 to 300, and the roving-spandex yarn may include a cotton staple sheath and the spandex core. Additionally, the woven textile fabric may also include from 170 to 200 ends per inch of warp yarns, from 100 to 110 picks per inch of the core spun yarn, and a total thread count from 270 to 310. A material content of the woven textile fabric may be approximately 97% to 98% cotton and approximately 2% to 3% spandex, by weight.
• Alternatively, the warp yarn may be 60% cotton and 40% polyester and have a 45 Ne count. The core spun yarn may be a roving-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier of 20 to 300, and the roving-spandex yarn may include a cotton staple sheath and the spandex core. The woven textile fabric may also include from 148 to 170 ends per inch of warp yarns, from 88 to 100 picks per inch of the core spun yarn, and
• a total thread count from 240 to 270. A material content of the woven textile fabric may be approximately 72% cotton, approximately 25% polyester, and approximately 3% spandex, by weight.
• The warp yarn may be 100% cotton and have a 60 Ne count, and the core spun yarn may be a poly-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier of 20 to 300. The poly-spandex yarn may include the spandex core and a sheath including a set of intermingled polyester filaments derived from a polyester strand, and the poly-spandex yarn may have a denier of at least 95. The woven textile fabric may also include from 170 to 200 ends per inch of warp yarns, from 70 to 80 picks per inch of the core spun yarn, a total thread count from 250 to 270. A material content of the woven textile fabric may be approximately 94% to 95% polyester and approximately 5% to 6% spandex, by weight.
• The warp yarn may be 60% cotton and 40% polyester and have a 45 Ne count, while the core spun yarn may be a poly-spandex yarn and have a 90 Ne count including the spandex core. The spandex core may have a denier of 20 to 300. Also, the poly-spandex yarn may include the spandex core and a sheath including a set of intermingled polyester filaments derived from an oriented polyester yarn. The woven textile fabric may also include from 148 to 170 ends per inch of warp yarns, from 88 to 100 picks per inch of the core spun yarn, and a total thread count from 250 to 270. A material content of the woven textile fabric may be approximately 37% cotton, approximately 61% polyester, and approximately 2% spandex, by weight.
• The methods and devices disclosed herein may be implemented in any means for achieving the various aspects. Other features will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
• Example embodiments are illustrated by way of example and not limitation in the Figures of the accompanying drawings, in which like references indicate similar elements and in which:
• FIG. 1 shows a polyester-spandex core spun yarn fabrication view, including an oriented polyester yarn and a spandex core, according to one embodiment.
• FIG. 2 shows a roving-spandex core spun yarn fabrication view, including a roving thread and a spandex core, according to one embodiment.
• FIG. 3 shows a reactive fabric bedding view showing an elastane weft bedding featuring a core spun yarn, according to one embodiment.
• FIG. 4 shows a process flow for the fabrication of the polyester-spandex core spun yarn ofFIG. 1, according to one embodiment.
• FIG. 5 shows a process flow for the fabrication of the roving-spandex core spun yarn ofFIG. 2, according to one embodiment
• Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
• Example embodiments, as described below, may be used to provide a method, an article of manufacture, device and/or a system of production of high cotton number or low denier core spun yarn for weaving of reactive fabric and enhanced bedding
• In one embodiment, a method of producing a core spun yarn includes drawing a partially oriented yarn from a polyester supply package through a primary input roller to form an oriented polyester yarn, and drawing the oriented polyester yarn through a secondary input roller. The method further includes drawing the oriented polyester yarn through a primary heater, exposing the oriented polyester yarn to a cooling plate, and drawing the oriented polyester yarn through a friction twisting unit using an intermediate roller. The method also includes drawing a spandex core from a spandex bobbin to become associated with the oriented polyester yarn at a supporting guide located between the friction twisting unit and the intermediate roller.
• The method includes drawing both the spandex core and the oriented polyester yarn through an intermingling jet, and texturizing the oriented polyester yarn using the intermingling jet using a hot air punching technique. Also included is twisting the oriented polyester yarn around the spandex core using the intermingling jet and the friction twisting unit, as well as drawing the oriented polyester yarn and the spandex core through a NFR roller after the intermingling jet. Finally, the method includes heating the oriented polyester yarn and the spandex core using a secondary heater to form the core spun yarn.
• The primary heater and the secondary heater may be set to a temperature between 50° C. and 200° C. Also, the cooling plate may be set to a temperature between 0° C. and 40° C. The intermingling jet may apply a uniform air pressure to the oriented polyester yarn to provide a counter-twist opposing the friction twisting unit. Additionally, the friction twisting unit may manipulate the oriented polyester yarn such that the oriented polyester yarn gains a texture and/or a weaving stability. Also, the manipulation may include a twisting and/or a detwisting.
• The method may include fixing a torsion of the oriented polyester yarn by translating a twist imparted by the friction twisting unit through the oriented polyester yarn back to the primary heater. The secondary input roller may be a twist-stopper preventing the twist from propagating to the polyester supply package. The spandex core may have a denier of 20 to 300.
• In another embodiment, a method of producing a core spun yarn includes drawing a roving thread from a roving bobbin through a roving guide, an aft drafting roller, and a mid drafting roller to a front drafting roller. The method further includes drawing a spandex core from a spandex bobbin using a guide roller, associating the roving thread and the spandex core by drawing the roving thread and the spandex core in an approximately parallel fashion through the front drafting roller, and drawing the roving thread and the spandex core through a lappet hook and an anti-ballooning guide. Finally, the method includes winding the roving thread and the spandex core on a ring-frame bobbin including a ring traveler attached to a rotatable ring. A circular motion of the ring traveler around the ring-frame bobbin causes the roving thread to twist around the spandex core, forming the core spun yarn. The roving thread may include cotton staple fibers and/or polyester staple fibers.
• In yet another embodiment, a woven textile fabric includes a warp yarn and a weft yarn. The weft yarn is a core spun yarn having a spandex core, and the woven textile fabric is a sateen weave or a plain weave. The woven textile fabric may assume a native state in the absence of external strain, and may assume a first distributed state when experiencing a first strain. Furthermore, the woven textile fabric may assume a second distributed state when experiencing a second strain. The first distributed state may include a slight stretch of the weft yarn which inhibits wrinkles while inhibiting airflow through the woven textile fabric. The second distributed state may include a further stretching of the weft yarn which may permit an enhanced airflow through the woven textile fabric.
• The warp yarn may be 100% cotton and have a 60 Ne count, while the core spun yarn may be a roving-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier from 20 to 300, and the roving-spandex yarn may include a cotton staple sheath and the spandex core. Additionally, the woven textile fabric may also include from 170 to 200 ends per inch of warp yarns, from 100 to 110 picks per inch of the core spun yarn, and a total thread count from 270 to 310. A material content of the woven textile fabric may be approximately 97% to 98% cotton and approximately 2% to 3% spandex, by weight.
• Alternatively, the warp yarn may be 60% cotton and 40% polyester and have a 45 Ne count. The core spun yarn may be a roving-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier of 20 to 300, and the roving-spandex yarn may include a cotton staple sheath and the spandex core. The woven textile fabric may also include from 148 to 170 ends per inch of warp yarns, from 88 to 100 picks per inch of the core spun yarn, and
• a total thread count from 240 to 270. A material content of the woven textile fabric may be approximately 72% cotton, approximately 25% polyester, and approximately 3% spandex, by weight.
• The warp yarn may be 100% cotton and have a 60 Ne count, and the core spun yarn may be a poly-spandex yarn and have a 60 Ne count including the spandex core. The spandex core may have a denier of 20 to 300. The poly-spandex yarn may include the spandex core and a sheath including a set of intermingled polyester filaments derived from a polyester strand, and the poly-spandex yarn may have a denier of at least 95. The woven textile fabric may also include from 170 to 200 ends per inch of warp yarns, from 70 to 80 picks per inch of the core spun yarn, a total thread count from 250 to 270. A material content of the woven textile fabric may be approximately 94% to 95% polyester and approximately 5% to 6% spandex, by weight.
• The warp yarn may be 60% cotton and 40% polyester and have a 45 Ne count, while the core spun yarn may be a poly-spandex yarn and have a 90 Ne count including the spandex core. The spandex core may have a denier of 20 to 300. Also, the poly-spandex yarn may include the spandex core and a sheath including a set of intermingled polyester filaments derived from an oriented polyester yarn. The woven textile fabric may also include from 148 to 170 ends per inch of warp yarns, from 88 to 100 picks per inch of the core spun yarn, and a total thread count from 250 to 270. A material content of the woven textile fabric may be approximately 37% cotton, approximately 61% polyester, and approximately 2% spandex, by weight.
• FIG. 1 shows a polyester-spandex core spun yarn fabrication view, including an oriented polyester yarn and a spandex core, according to one embodiment. Specifically,FIG. 1 shows a poly-spandex yarn100, a set of intermingledpolyester filaments102, aspandex core104, asheath105, apolyester supply package106, a partially orientedyarn108, aprimary input roller110, an orientedpolyester yarn112, asecondary input roller114, aprimary heater116, acooling plate118, afriction twisting unit120, aspandex bobbin122, a supportingguide124, anintermediate roller126, an interminglingjet128, anNFR roller130, asecondary heater132, anoutput roller134, anoil applicator136, atraverse box138, a take-uproller140, and a poly-spandex bobbin145.
• The poly-spandex yarn100 may be a yarn made out of a combination of polyester and spandex. Polyester is a synthetic resin in which the polymer units are linked by ester groups. Spandex is a type of stretchy polyurethane fabric. The set of intermingledpolyester filaments102 may be a combination of thin polyester strands. Thespandex core104 may be the strand of spandex material which serves as the core of a core spun yarn. The spandex core will be wrapped in a sheath made of a yarn or other material.
• Thesheath105 may be a close fitting cover for something, such as a core. By wrapping a core (e.g. a spandex core, etc.) in a sheath made out of a different material (e.g. cotton, polyester, etc.), one may obtain the benefits of both materials. Thepolyester supply package106 may be a spool, a reel, or other form of packaging for a polyester thread or yarn. The partially orientedyarn108 may be polyester yarn as it is just coming off of a container, such as a polyester supply package. Theprimary input roller110 may be a roller through which a yarn may pass. The orientedpolyester yarn112 may be a polyester yarn after passing through a primary input roller. Thesecondary input roller114 may be a roller through which a yarn may pass. In some embodiments, thesecondary input roller114 may also serve as a twist-stopper that prevents a twist from propagating to the polyester supply package.
• Theprimary heater116 may be a device for supplying heat to a yarn or thread being drawn through it. Thecooling plate118 may be a device used to chill or cool a thread or yarn which is passing through it. Thefriction twisting unit120 may twist/detwist a set of the filaments comprising the orientedpolyester yarn112 such that the oriented polyester yarn1121 gains a texture (e.g., such that within the resulting textile that the poly-spandex yarn100 may be woven into gains in “body” and/or heft) and may also provide a low stability interlacing in a weaving process. Thefriction twisting unit120 may also help to intermingle the filaments comprising the orientedpolyester yarn112 such that they provide a more uniform and comprehensive instance of thesheath105.
• Thespandex bobbin122 may be a cylinder or cone holding a spandex thread or yarn. The supportingguide124 may be a guide which facilitates the introduction of the oriented polyester yarn to the polyester core, which may be coming from different directions. Theintermediate roller126 may be a roller which may be used to pull one or more yarns, filaments, and/or threads through a system. The interminglingjet128 may be an air jet used to texturize, combine, or otherwise manipulate yarns and threads. TheNFR roller130 may be a bearing supported roller type freewheel. In some embodiments, the NFR roller may have no sealing.
• Thesecondary heater132 may be an additional heater. Theoutput roller134 may be a roller which may be used to pull a yarn through a process or system. Theoil applicator136 may be a device for the application of conning oil near the end of a yarn fabrication process. Thetraverse box138 may be a device which assists in the storage of yarn, such as the core spun yarn being fabricated inFIGS. 1 and 2, on a bobbin. The take-uproller140 may be a roller which assists in the storage of a yarn. The poly-spandex bobbin145 may be a bobbin designated for the storage of a poly-spandex yarn.
• FIG. 1 is a polyester-spandex core spun yarn fabrication view showing production of a poly-spandex yarn of a core spun construction having a spandex core and a sheath of intermingled polyester filaments derived from an oriented polyester yarn that is twisted around the spandex core by a friction twisting unit and an intermingling yet, the poly-spandex yarn that results being subsequently spun on a poly-spandex bobbin for use in a loom apparatus, according to one or more embodiments.
• The poly-spandex yarn100 comprises aspandex core104 of a denier of 20 to 300 along with thesheath105 comprising the intermingledpolyester filaments102. The intermingledpolyester filaments102 are derived from the orientedpolyester yarn112 that is twisted around thespandex core104. A process of producing the poly-spandex yarn100 begins by drawing the partially orientedyarn108 from thepolyester supply package106 to theprimary input roller110. The partially orientedyarn108 may then be referred to as the orientedpolyester yarn112 which may then enter thesecondary input roller114. Thesecondary input roller114 may be a twist-stopper that prevents a twist from propagating to thepolyester supply package106. The orientedpolyester yarn112 may then be drawn through theprimary heater116. Theprimary heater116 may be heated to a temperature between 50° C. and 200° C. In one preferred embodiment, the primary heater may be set to 190° C. After leaving theprimary heater116, the orientedpolyester yarn112 may then be exposed to thecooling plate118 that may be set at a temperature between 0° C. and room temperature (e.g., about 20-25° C.). The cooling plate may also be set at temperatures between 25° C. and 40° C., and in one preferred embodiment 38° C.
• Theintermediate roller126 may draw the orientedpolyester yarn112 from thecooling plate118 to thefriction twisting unit120. The friction twisting unit120 (e.g., an FTU) may twist/detwist a set of the filaments comprising the orientedpolyester yarn112 such that the oriented polyester yarn1121 gains a texture (e.g., such that within the resulting textile that the poly-spandex yarn100 may be woven into gains in “body” and/or heft) and may also provide a low stability interlacing in a weaving process. Thefriction twisting unit120 may also help to intermingle the filaments comprising the orientedpolyester yarn112 such that they provide a more uniform and comprehensive instance of thesheath105. The twist imparted by thefriction twisting unit120 may be translated through the orientedpolyester yarn112 back to theprimary heater116, which, in conjunction with thecooling plate118, may “fix” the molecular structure of the twisted filaments of the orientedpolyester yarn112, imbuing it with a “memory” of torsion.
• Thespandex core104 may be drawn from thespandex bobbin122 to become associated with the orientedpolyester yarn112 at the supportingguide124, which may be located between thefriction twisting unit120 and theintermediate roller126. Theintermediate roller126 may draw both the orientedpolyester yarn112 and thespandex core104 through the interminglingjet128. A combination of an action of the interminglingjet128, which may texturize the orientedpolyester yarn112 through a hot air punching technique, along with the friction twisting unit, may twist the orientedpolyester yarn112 around thespandex core104. The interminglingjet128 may apply a uniform air pressure to the orientedpolyester yarn112 in order to provide counter-twist to thefriction twisting unit120. The orientedpolyester yarn112 may then be heated by thesecondary heater132. Thesecondary heater132 may be set to between 50° C. and 200° C. In one preferred embodiment, the intermingling jet115 may be set to a pressure of 2 bars and thesecondary heater132 may be set to a temperature of 170° C. Upon leaving the interminglingjets128, the orientedpolyester yarn112 and thespandex core104 may enter theNFR Roller130, which may be a bearing supported freewheel-type roller without any sealing.
• The combination of thespandex core104 with the orientedpolyester yarn112, upon exiting thesecondary heater132, may be referred to as the poly-spandex yarn100. The poly-spandex yarn100 may have a conning oil applied by theoil applicator136. The conning oil applied by theoil applicator136 may act as a lubricant, reducing a friction between two or more yarns (e.g., several of the poly-spandex yarns100) and between one or more yarns and a loom apparatus (e.g., metallic components the poly-spandex yarns100 may contact). The conning oil may also minimize a static charge formation of synthetic yarns.
• After passing theoil applicator136, the poly-spandex yarn100 may be drawn through atraverse box138 by a take-uproller140 to be wound on the poly-spandex bobbin145. The poly-spandex bobbin145 may be fed into a loom apparatus as a weft yarn of a woven textile (e.g., as disclosed above, the third woven textile and/or the fourth woven textile).
• FIG. 2 shows a roving-spandex core spun yarn fabrication view, including a roving thread and a spandex core, according to one embodiment. Specifically,FIG. 2 shows a roving-spandex yarn200, aroving thread202, aroving bobbin206, aroving guide208, an aft drafting roller210, amid drafting roller212, afront drafting roller214, aguide roller216, alappet hook218, ananti-ballooning guide220, aring traveler222, a ring-frame bobbin224, and a roving-spandex bobbin245.
• The roving-spandex yarn200 may be a yarn made out of a combination of a roving fiber and a spandex material. Theroving thread202 may be long and narrow bundle of fibers. For example, the roving202 may be produced during the process of making yarn from raw cotton, polyester fibers, and/or a combination of cotton and polyester fibers. Theroving bobbin206 may be a cylinder or cone which holds a roving. Theroving guide208 may be a device which helps ensure the roving is fed correctly into the aft drafting roller. The aft drafting roller210 may be the first drafting roller the roving is passed through.
• Themid drafting roller212 and thefront drafting roller214 may be rollers which draw the roving thread into the system, maintaining a proper level of tension to make various properties of the thread uniform. Theguide roller216 may be a roller which assists with the introduction of the spandex core to the roving thread. Thelappet hook218 and theanti-ballooning guide220 may be devices which assist with maintaining the ballooning of the thread within a certain limit. Thering traveler222 may be a hook which assists with the winding of the yarn on the bobbin. The roving-spandex bobbin245 may be a cylinder or cone which may be used to hold a roving-spandex yarn.
• The roving-spandex yarn200 comprises aspandex core104 of a denier between of 20 to 300 along with thesheath105 comprising theroving thread202. Creating a core spun yarn with a 60-80 Ne count may be difficult, and may require long staple yarn fibers, a compact spinning with a high twist. To form the roving-spandex yarn200, theroving thread202 is drawn from theroving bobbin206, through theroving guide208, the aft drafting roller210 and themid drafting roller212 until it reaches thefront drafting roller214. Theroving thread202 may be a thread made of cotton staple fibers and/or polyester staple fibers. Proximate to a drafting zone associated with thefront drafting roller214, thespandex core104 is drawn from thespandex bobbin122 by theguide roller216. Thespandex core104 and theroving thread202 may become associated near the drafting zone, and drawn in an approximately parallel fashion through thefront drafting roller214.
• Thespandex core104 and theroving thread202 may then be drawn through thelappet hook218 and ananti-ballooning guide220 to be wound on a ring-frame bobbin224. The ring-frame bobbin224 uses aring traveler222. Thering traveler222 may be attached to a ring that may rotate. A rapid circular motion of thering traveler222 around the ring-frame bobbin224 may cause theroving thread202 to twist around thespandex core104, which may form thesheath105 of the roving-spandex yarn200. Thering traveler222 may then wrap the roving-spandex yarn200 on the ring-frame bobbin224 at the same time a spindle of the ring-frame bobbin245 rotates, forming the roving-spandex bobbin245.
• FIG. 3 shows a reactive fabric bedding view showing an elastane weft bedding featuring a core spun yarn, according to one embodiment. Specifically,FIG. 3 shows an elastane weft bedding300, a user301, a core spunweft302, a first distributedstate303A and a second distributedstate303B, awarp304, an inhibitedairflow306, and anenhanced airflow308.
• The elastane weft bedding300 may be a bed sheet made from the first woven textile, the second woven textile, the third woven textile, or the fourth woven textile, and which may be a different woven textile also made from the poly-spandex yarn100 and/or the roving-spandex yarn200. The user301 may be a customer, a consumer, a guest at a hotel, or any other individual who may make use of the elastane weft bedding. The core spunweft302 may be a core spun yarn, such as the polyester-spandex core spun yarn or the roving-spandex core spun yarn, which is being employed as a weft yarn in a textile. The first distributedstate303A and the second distributedstate303B may be states of a textile fabric which may be defined by the degree to which a stretchable weft is being stretched, due to a force being applied (e.g. the strain of being fitted on a mattress, the strain due to a user resting on top of the fabric, etc.) Thewarp304 may be the yarn which is interlaced with the weft in a textile fabric. The inhibitedairflow306 may be an air flow that is prevented from passing through the elastane weft bedding. Theenhanced airflow308 may be additional or increased air which flows through the elastane weft bedding.
• The present disclosure related to a number of embodiments of the woven textile that have a relatively small diameter of core spun yarn, resulting in a higher thread count and the realization of a reactive fabric that may be used as a bedding (e.g., a bed sheet, a pillow case, a duvet cover) with enhanced comfort and functionality. In one embodiment, a first woven textile comprises from 170 to 200 ends per inch of warp yarns and from 100 to 110 picks per inch of a core spun yarn (the core spun yarn being a weft of the first woven textile fabric) that is a roving-spandex yarn (e.g., the roving-spandex yarn200 ofFIG. 2). A spandex material may also be known as a Lycra™, and/or an elastane. The roving-spandex yarn has a sheath comprising a roving that is a cotton staple and a core that is a spandex core. The total thread count of the first woven textile may be 270 to 310. The first woven textile may have a 100% cotton warp, and the cotton warp may have a 60 Ne Count (Ne may also be known as an “English Cotton Number,” a “cotton count,” and/or a “count,” and may be a measure of the weight in pounds per 840 yard lengths of a yarn). The roving-spandex yarn may have a 60 Ne count, including the spandex core. The spandex core may have a denier of 20 to 300, and in a preferred embodiment between 20 and 60. A material content of the roving-spandex yarn may be 92.0% to 93.0% cotton and 7.0% to 8.0% spandex, by weight. A material content of the first woven textile may be approximately 97.0% to 98.0% cotton and approximately 2.0% to 3.0% spandex, by weight. The first woven textile may have a tensile strength in the warp direction of 40 to 50 kgf/m2 and a tensile strength in the weft direction of 12 to 16 kgf/m2.
• In another embodiment, a second woven textile comprises from 148 to 170 ends per inch of warp yarns and from 88 to 100 picks per inch of a core spun yarn (the core spun yarn being a weft of the second woven textile fabric) that is a roving-spandex yarn (e.g., the roving-spandex yarn200 ofFIG. 2). The roving-spandex yarn has a sheath comprising a roving that is a cotton staple and a core that is a spandex core. The total thread count of the second woven textile may be 240 to 270. The second woven textile may have a polyester-cotton warp, and the polyester-cotton warp may have a 45 Ne count. The roving-spandex yarn may have a 60 Ne count, including the spandex core. The cotton-polyester warp may be 60% cotton and 40% polyester. The spandex core may have a denier of 20 to 300. A material content of the roving-spandex yarn may be 92.0% to 93% cotton and 7% to 8% spandex, by weight. A material content of the second woven textile may be approximately 72.0% cotton, approximately 25% polyester, and approximately 3% spandex, by weight. The second woven textile may have a tensile strength in the warp direction of 55 to 65 kgf/m2 and a tensile strength in the weft direction of 15 to 18 kgf/m2.
• In yet another embodiment, a third woven textile comprises from 170 to 200 ends per inch of warp yarns and from 70 to 80 picks per inch of a core spun yarn (the core spun yarn being a weft of the third woven textile) that is a poly-spandex yarn (e.g., the poly-spandex yarn100 ofFIG. 1). The poly-spandex yarn has a sheath comprising a set of intermingled polyester filaments derived from a polyester strand and the poly-spandex yarn may have a core that is a spandex core. The total thread count may be 250 to 270. The woven textile may have a cotton warp that is 100% cotton, and the cotton warp may have a 60 Ne count. A denier of the polyester strand may be 75, a denier of the spandex core may be 20, and the denier of the poly-spandex yarn may be about 95. However, the denier of the poly-spandex yarn may be slightly great than 95 due to an increase in a linear density resulting form the twisted structure of the polyester around the spandex core. The spandex core may have a denier of 20 to 300. A material content of the third woven textile may be 94.0% to 95% polyester and 5% to 6% spandex, by weight. The third woven textile may have a tensile strength in the warp direction of 40 to 45 kgf/m2 and a tensile strength in the weft direction of 16 to 20 kgf/m2.
• In yet another embodiment, a fourth woven textile comprises from 148 to 170 ends per inch of warp yarns and from 88 to 100 picks per inch of a core spun yarn (the core spun yarn being a weft of the woven textile) that is a poly-spandex yarn (e.g., the poly-spandex yarn100 ofFIG. 1). The poly-spandex yarn has a sheath comprising a set of intermingled polyester filaments derived from an oriented polyester yarn and the poly-spandex yarn may have a core that is a spandex core. The total thread count may be 250 to 270. The fourth woven textile may have a polyester-cotton warp, and the polyester-cotton warp may have a 45 Ne count. The poly-spandex yarn may have a 90 Ne count, including the spandex core (although there is no cotton, the English Cotton Number may still be used as a measure to approximate diameter and/or to measure a linear density). The spandex-polyester warp may be 60% cotton and 40% polyester. The spandex core may have a denier of 20 to 300. A material content of the roving-spandex yarn may be 94.0% to 95% polyester and 5% to 6% spandex, by weight. A material content of the fourth woven textile may be approximately 37.0% cotton, 61.0% polyester, and 2.0% spandex, by weight. The fourth woven textile may have a tensile strength in the warp direction of 50 to 60 kgf/m2 and a tensile strength in the weft direction of 15 to 18 kgf/m2.
• The poly-spandex yarn100 and/or the roving-spandex yarn200 may be used as a feed yarn for a loom apparatus to form a woven textile (e.g., any of the first woven textile, the second woven textile, the third woven textile, and the fourth woven textile disclosed above). In one preferred embodiment, the loom apparatus is an air jet loom apparatus such as a Picanol Omni Plus® or a Picanol Omni Plus® 800. In the air jet loom apparatus, a picking cycle should be completed as quickly as possible during a weft insertion event. For example, if a normal weft insertion would begin at a pick departure of 75° and end with a pick arrival at 255°, the air jet loom apparatus should be adjusted for the a pick departure of 80° and a pick arrival of 245°. A drive time of a main valve and a relay valve may be increased for usage of a spandex weft. For example, the drive time of the a main valve may be increased from 90° to 150° and the drive time of the relay valve may be increased from 70° to 125°. A pressure of a main nozzle may be increased from 4.5 bars to 5.5 bars, and a pressure of a set of relay nozzles may be increased from 5 bars to 6 bars. For the air jet loom apparatus of Picanal brand, an ELCA holding pressure may be 1.5 kg/cm3 maximum.
• A holding pressure of a main nozzle MB (Main Breeze) may be set to 150 KPa, and a tandem nozzle holding pressure may be set per a spandex weft requirement of a manufacturer of the looming apparatus. Additionally, one or more extra instances of the relay nozzle may be added near an end of a side selvedges of the woven textile, after a first filling detector. The extra instance of the relay nozzle may keep the poly-spandex yarn100 and/or the roving-spandex yarn200 at a required tension at the end of a picking cycle of the air jet loom apparatus. The loom apparatus may be set up in almost any of a type of weave, but in one preferred embodiment the type of weave used to form the first woven fabric, the second woven fabric, the third woven fabric, and/or the fourth woven fabric may be a sateen weave or a plain weave.
• The woven textile that results from the use of the poly-spandex yarn100 and/or the roving-spandex yarn200 may be used to form a variety of useful and enhanced products. In one or more primary embodiments, the fabric may be used to for a bedding (e.g., a bed sheet, a pillow case, a duvet cover). The woven textile fabric may increase a sleep experience for several reasons. One reason may be that the woven textile comprised of the poly-spandex yarn100 and/or the roving-spandex yarn200 may lend a global stretch effect to the bedding. A lack of wrinkles is associated with a positive sleeping experience. Traditional bed sheets attempt to diminish wrinkles by using elastic bands around the corners of the bed-sheet, two edges of the bed sheet and/or the entire parameter of the bed-sheet, but no stretch effect is imparted to the bed sheet itself. In contrast, the bedding made from poly-spandex yarn100 and/or the roving-spandex yarn200 may be able to stretch over the surface of the bed sheet, which may increase comfort as a result of the uniform surface under constant tension from two opposite edges of the sheet.
• Another benefit may be that the woven textile comprising poly-spandex yarn100 and/or the roving-spandex yarn200 may provide increased comfort as the weight of a person on top of the bed-sheet causes a stretching action in the direction of the core-spun yarn (e.g., the weft), which may temporarily increase the distance between a set of perpendicular yarns forming the weft, creating an enhanced airflow. The enhanced airflow may, among many benefits, cause the bed-sheet to feel cooler and may allow moisture or sweat to dry faster, further causing the comfort against the human skin. In one respect, if the thread count of the bed-sheet textile is defined as the number of yarns in both one inch of the warp direction and one inch of the weft direction when a fabric of the bed-sheet is in a native state, the thread count may decrease when a human weight is placed on, or moves over, the surface of the be bed-sheet due to the stretching of the fabric. However, in this instance a dynamic decreased in thread count experienced in an in-use state, rather than decrease comfort, may increase comfort by increasing a breathability of the bed sheet. Furthermore, no decrease in comfort may occur because the diameter of a core spun weft and a warp of the woven textile do not substantially change.
• The advantages of the enhanced bedding are illustrated inFIG. 3.FIG. 3 is a reactive fabric bedding view showing an elastane weft bedding created with either the poly-spandex yarn ofFIG. 1 and/or the roving-spandex yarn ofFIG. 2, a core spun weft of the elastane weft bedding having a stretch capability that transitions from a native state to a first distributed state that prevents wrinkles when placed in position over a bed, and further transitions from the first distributed state to a second distributed state when weight is placed against the elsastane weft bedding, the second distributed state separating a set of warp yarns to promote an enhanced airflow that causes an improved sleep experience for a user, according to one or more embodiments.
• In the embodiment ofFIG. 3, the elastane weft bedding300 may be stretched over a bed of a user301. Before being placed on the bed, the elastane weft bedding300 may be in a native state (not shown in the embodiment ofFIG. 3) that may represent a least stretched aspect of the core spun weft. Once placed on the bed, the elastane weft bedding300 may enter the first distributedstate303A wherein the core spunweft302 may have a slight stretch. The first distributedstate303A may allow the elastane weft bedding300 to stay secure on the bed and may inhibit wrinkles, promoting a more comfortable sleeping experience. In the first distributed state, the inhibitedairflow306 may still exist as a set of pores between a set of interlacings of the elastane weft bedding may be relatively small. However, when the user301 lays on top of the elastane weft bedding300, a location of pressure may cause the elastane weft bedding to enter the second distributedstate303B. The second distributedstate303B may increase the pore size between the interlacings, allowing theenhanced airflow308 that may further enhance the sleeping experience.
• FIG. 4 shows a process flow for the fabrication of the polyester-spandex core spun yarn ofFIG. 1, according to one embodiment. Inoperation402, a partially oriented yarn may be drawn from a polyester supply package through a primary input roller to form an oriented polyester yarn. Inoperation404, the oriented polyester yarn may be drawn through a secondary input roller. Inoperation406, the oriented polyester yarn may be drawn through a primary heater. Furthermore, inoperation408, the oriented polyester yarn may be exposed to a cooling plate. Inoperation410, the oriented polyester yarn may be drawn through a friction twisting unit using an intermediate roller.
• Inoperation412, a spandex core may be drawn from a spandex bobbin to become associated with the oriented polyester yarn at a supporting guide located between the friction twisting unit and the intermediate roller. Inoperation414, both the spandex core and the oriented polyester yarn may be drawn through an intermingling jet. Inoperation416, the oriented polyester yarn may be texturized using the intermingling jet using a hot air punching technique. Inoperation418, the oriented polyester yarn may be twisted around the spandex core using at least one of the intermingling jet and the friction twisting unit. Inoperation420, the oriented polyester yarn and the spandex core may be drawn through a NFR roller after the intermingling jet. Finally, inoperation422, the oriented polyester yarn and the spandex core may be heated using a secondary heater to form the core spun yarn.
• FIG. 5 shows a process flow for the fabrication of the roving-spandex core spun yarn ofFIG. 2, according to one embodiment. Inoperation502, a roving thread may be drawn from a roving bobbin through a roving guide, an aft drafting roller, and a mid drafting roller to a front drafting roller. Inoperation504, a spandex core may be drawn from a spandex bobbin using a guide roller. Inoperation506, the roving thread and the spandex core may be associated by drawing the roving thread and the spandex core in an approximately parallel fashion through the front drafting roller. Inoperation508, the roving thread and the spandex core may be drawn through a lappet hook and an anti-ballooning guide. Inoperation510, the roving thread and the spandex core may be wound on a ring-frame bobbin comprising a ring traveler attached to a rotatable ring, wherein a circular motion of the ring traveler around the ring-frame bobbin causes the roving thread to twist around the spandex core, forming the core spun yarn.
• The structures and modules in the Figures may be shown as distinct and communicating with only a few specific structures and not others. The structures may be merged with each other, may perform overlapping functions, and may communicate with other structures not shown to be connected in the Figures. Accordingly, the specification and/or drawings may be regarded in an illustrative rather than a restrictive sense.

Claims (20)

What is claimed is:

1. A method of producing a core spun yarn, comprising:

drawing a partially oriented yarn from a polyester supply package through a primary input roller to form an oriented polyester yarn;

drawing the oriented polyester yarn through a secondary input roller;

drawing the oriented polyester yarn through a primary heater;

exposing the oriented polyester yarn to a cooling plate;

drawing the oriented polyester yarn through a friction twisting unit using an intermediate roller;

drawing a spandex core from a spandex bobbin to become associated with the oriented polyester yarn at a supporting guide located between the friction twisting unit and the intermediate roller;

drawing both the spandex core and the oriented polyester yarn through an intermingling jet;

texturizing the oriented polyester yarn using the intermingling jet using a hot air punching technique;

twisting the oriented polyester yarn around the spandex core using at least one of the intermingling jet and the friction twisting unit;

drawing the oriented polyester yarn and the spandex core through a NFR roller after the intermingling jet; and

heating the oriented polyester yarn and the spandex core using a secondary heater to form the core spun yarn.

2. The method ofclaim 1, wherein at least one of the primary heater and the secondary heater is set to a temperature between 50° C. and 200° C.

3. The method ofclaim 1, wherein the cooling plate is set to a temperature between 0° C. and 40° C.

4. The method ofclaim 1, wherein the intermingling jet applies a uniform air pressure to the oriented polyester yarn to provide a counter-twist opposing the friction twisting unit.

5. The method ofclaim 1:

wherein the friction twisting unit manipulates the oriented polyester yarn such that the oriented polyester yarn gains at least one of a texture and a weaving stability; and

wherein the manipulation comprises one of a twisting and a detwisting.

6. The method ofclaim 1, further comprising:

fixing a torsion of the oriented polyester yarn by translating a twist imparted by the friction twisting unit through the oriented polyester yarn back to the primary heater,

wherein the secondary input roller is a twist-stopper preventing the twist from propagating to the polyester supply package.

7. The method ofclaim 1, wherein the spandex core has a denier of 20 to 300.

8. A method of producing a core spun yarn, comprising:

drawing a roving thread from a roving bobbin through a roving guide, an aft drafting roller, and a mid drafting roller to a front drafting roller;

drawing a spandex core from a spandex bobbin using a guide roller;

associating the roving thread and the spandex core by drawing the roving thread and the spandex core in an approximately parallel fashion through the front drafting roller;

drawing the roving thread and the spandex core through a lappet hook and an anti-ballooning guide; and

winding the roving thread and the spandex core on a ring-frame bobbin comprising a ring traveler attached to a rotatable ring,

wherein a circular motion of the ring traveler around the ring-frame bobbin causes the roving thread to twist around the spandex core, forming the core spun yarn.

9. The method ofclaim 8, wherein the spandex core has a denier from 20 to 300.

10. The method ofclaim 8, wherein the roving thread comprises at least one of cotton staple fibers and polyester staple fibers.

11. A woven textile fabric, comprising:

a warp yarn; and

a weft yarn,

wherein the weft yarn is a core spun yarn having a spandex core,

wherein the woven textile fabric is at least one of a sateen weave and a plain weave.

12. The woven textile fabric ofclaim 11:

wherein the woven textile fabric assumes a native state in the absence of external strain,

wherein the woven textile fabric assumes a first distributed state when experiencing a first strain,

wherein the woven textile fabric assumes a second distributed state when experiencing a second strain,

wherein the first distributed state comprises a slight stretch of the weft yarn which inhibits wrinkles while inhibiting airflow through the woven textile fabric, and

wherein the second distributed state comprises a further stretching of the weft yarn which permits an enhanced airflow through the woven textile fabric.

13. The woven textile fabric ofclaim 11:

wherein the warp yarn is 100% cotton and has a 60 Ne count,

wherein the core spun yarn is a roving-spandex yarn and has a 60 Ne count including the spandex core,

wherein the spandex core has a denier from 20 to 300, and

wherein the roving-spandex yarn comprises a cotton staple sheath and the spandex core.

14. The woven textile fabric ofclaim 13, further comprising:

from 170 to 200 ends per inch of warp yarns;

from 100 to 110 picks per inch of the core spun yarn; and

a total thread count from 270 to 310,

wherein a material content of the woven textile fabric is approximately 97% to 98% cotton and approximately 2% to 3% spandex, by weight.

15. The woven textile fabric ofclaim 11:

wherein the warp yarn is 60% cotton and 40% polyester and has a 45 Ne count,

wherein the core spun yarn is a roving-spandex yarn and has a 60 Ne count including the spandex core,

wherein the spandex core has a denier of 20 to 300, and

wherein the roving-spandex yarn comprises a cotton staple sheath and the spandex core.

16. The woven textile fabric ofclaim 15, comprising:

from 148 to 170 ends per inch of warp yarns;

from 88 to 100 picks per inch of the core spun yarn; and

a total thread count from 240 to 270,

wherein a material content of the woven textile fabric is approximately 72% cotton, approximately 25% polyester, and approximately 3% spandex, by weight.

17. The woven textile fabric ofclaim 11:

wherein the warp yarn is 100% cotton and has a 60 Ne count,

wherein the core spun yarn is a poly-spandex yarn and has a 60 Ne count including the spandex core,

wherein the spandex core has a denier of 20 to 300,

wherein the poly-spandex yarn comprises the spandex core and a sheath comprising a set of intermingled polyester filaments derived from a polyester strand, and

wherein the poly-spandex yarn has a denier of at least 95.

18. The woven textile fabric ofclaim 17, comprising:

from 170 to 200 ends per inch of warp yarns;

from 70 to 80 picks per inch of the core spun yarn; and

a total thread count from 250 to 270,

wherein a material content of the woven textile fabric is approximately 94% to 95% polyester and approximately 5% to 6% spandex, by weight.

19. The woven textile fabric ofclaim 11:

wherein the warp yarn is 60% cotton and 40% polyester and has a 45 Ne count,

wherein the core spun yarn is a poly-spandex yarn and has a 90 Ne count including the spandex core,

wherein the spandex core has a denier of 20 to 300, and

wherein the poly-spandex yarn comprises the spandex core and a sheath comprising a set of intermingled polyester filaments derived from an oriented polyester yarn.

20. The woven textile fabric ofclaim 19, comprising:

from 148 to 170 ends per inch of warp yarns;

from 88 to 100 picks per inch of the core spun yarn; and

a total thread count from 250 to 270,

wherein a material content of the woven textile fabric is approximately 37% cotton, approximately 61% polyester, and approximately 2% spandex, by weight.

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