YARN OF STAPLE FIBERS FROM MULTI-FILAMENTS BY STRETCHING AND CONTROLLED BREAKING AND ARTICLES MADE THEREFROM

Abstract

A single-strand yarn includes a plurality of intimately associated staple fibers made from N strands of multi-filaments by stretching and controlled breaking, and then spun by a spinning process, where N is a natural number. Within the single-strand yarn of a sampling length according to the invention, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length to the total number of the staple fibers, is equal to or greater than 60%. The sampling length is equal to or less than 10 meters. The setup fiber length is equal to or larger than 65 mm. The dispersion of the weight distribution in the average length of the single-strand yarn according to the invention is equal to or less than 60%.

Claims

1. A single-strand yarn, comprising: a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number, wherein within said single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said single-strand yarn is equal to or less than 60%, wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.

2. The single-strand yarn of claim 1, wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of said single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, said single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

3. A plied yarn, comprising: M single-strand yarns, being doubled or twisted together, M being an integer equal to or larger than 2, each single-strand yarn comprising: a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number, wherein within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%, wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.

4. The plied yarn of claim 3, wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of said single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, said single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

5. A textile article woven from a first single-strand yarn or a plied yarn by one selected from the group consisting of a weaving process, a non-weaving process, a knitting process, a warp knitting process, and a weft knitting process, the plied yarn comprising M second single-strand yarns which are doubled or twisted together, M being an integer equal to or larger than 2, the first single-strand yarn and each second single-strand yarn both comprising: a plurality of intimately associated staple fibers, being made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, N being a natural number, wherein within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, the sampling length is equal to or less than 10 meters, the setup fiber length is equal to or larger than 65 mm, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%, wherein the N strands of first multi-filaments are made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, and glass.

6. The textile article of claim 5, wherein a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments, a first fineness of the first single-strand yarn or each second single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments, the first single-strand yarn and each second single-strand yarn both have a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

7. The textile article of claim 6, wherein a number of neps on a surface of the textile article is equal to or less than 30/m.sup.2.

8. The textile article of claim 7, wherein the N strands of first multi-filaments are made of 316L stainless steel, the textile article is woven by the knitting process.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0021] The invention uses a plurality of intimately associated staple fibers made from multi-filaments by stretching and controlled breaking to spin into a single-strand yarn and a plied yarn, and a textile article is produced therefrom. In the invention, by controlling the stretch-breaking process, the dispersion of the length distribution of the staple fibers in the yarn is smaller, and the dispersion of the weight distribution of the average length of the yarn is smaller, so that the single-strand yarn and the plied yarn according to the invention have high strength and high diameter uniformity. The textile article woven from the yarns made from the stretch-broken staple fibers according to the invention has better smoothness. Some preferred embodiments and practical applications of this present invention would be explained in the following paragraph, describing the characteristics, spirit, and advantages of the invention.

[0022] A single-strand yarn according to a first preferred embodiment of the invention includes a plurality of intimately associated staple fibers. The plurality of intimately associated staple fibers are made from N strands of first multi-filaments by stretching and controlled breaking, and then are spun by a spinning process, where N is a natural number. The N strands of first multi-filaments are fed to a stretch-breaking machine to obtain a stretch-broken sliver, and then the stretch-broken sliver is fed into a spinning machine to be spun into the single-stranded yarn according to the invention.

[0023] In particular, within the single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%. The sampling length is equal to or less than 10 meters. The setup fiber length is equal to or larger than 65 mm. Moreover, a dispersion of a weight distribution in an average length of said single-strand yarn is equal to or less than 60%.

[0024] The N strands of first multi-filaments can be made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, glass, or other conductive or non-conductive materials. Thereby, the single-strand yarn according to the invention can be composed of single-material fibers or mixed-material fibers, and not limited to high-performance fibers.

[0025] In one embodiment, a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments. A first fineness of the single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments. The single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

[0026] A plied yarn according to a second preferred embodiment of the invention includes M single-strand yarns, where M is an integer equal to or larger than 2. The M single-strand yarns are doubled or twisted together.

[0027] Each single-strand yarn a plurality includes a plurality of intimately associated staple fibers. The plurality of intimately associated staple fibers are made from N strands of first multi-filaments by stretching and controlled breaking, and then are spun by a spinning process, where N is a natural number. The N strands of first multi-filaments are fed to a stretch-breaking machine to obtain a stretch-broken sliver, and then the stretch-broken sliver is fed into a spinning machine to be spun into the single-stranded yarn.

[0028] In particular, within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%. The sampling length is equal to or less than 10 meters. The setup fiber length is equal to or larger than 65 mm. Moreover, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%.

[0029] The N strands of first multi-filaments can be made of at least one selected from the group consisting of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, glass, or other conductive or non-conductive materials. Thereby, the plied yarn according to the invention can be composed of single-material fibers or mixed-material fibers, and not limited to high-performance fibers.

[0030] Similarly, in one embodiment, a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments. A first fineness of each single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments. Each single-strand yarn has a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

[0031] A textile article according to a third preferred embodiment of the invention is woven from a first single-strand yarn or a plied yarn by a textile process. The textile process can be a weaving process, a non-weaving process, a knitting process, a warp knitting process, a weft knitting process, or other textile process. The plied yarn includes M second single-strand yarns which are doubled or twisted together, where M is an integer equal to or larger than 2.

[0032] The first single-strand yarn and each second single-strand yarn a plurality both include a plurality of intimately associated staple fibers. The plurality of intimately associated staple fibers are made from N strands of first multi-filaments by stretching and controlled breaking, and then being spun by a spinning process, where N is a natural number. The N strands of first multi-filaments are fed to a stretch-breaking machine to obtain a stretch-broken sliver, and then the stretch-broken sliver is fed into a spinning machine to be spun into the single-stranded yarn.

[0033] In particular, within said one single-strand yarn of a sampling length, a ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%. The sampling length is equal to or less than 10 meters. The setup fiber length is equal to or larger than 65 mm. Moreover, a dispersion of a weight distribution in an average length of said one single-strand yarn is equal to or less than 60%.

[0034] The N strands of first multi-filaments can be made of copper, CuNi alloys, CuNiSi alloys, CuNiZn alloys, CuNiSn alloys, CuCr alloys, CuAg alloys, CuW alloys, FeCrAl alloys, silver, gold, lead, zinc, aluminum, nickel, brass, phosphor bronze, beryllium copper, nichrome, tantalum, tungsten, platinum, palladium, stainless steels, 316L stainless steel, titanium, titanium alloys, Ni—Cr—Mo—W alloy, zirconium, zirconium alloys, HASTELLOY® alloys, Nickel alloys, MONEL® alloys, ICONEL® alloys, FERRALIUM® alloy, NITRONIC® alloys, CARPENTER® alloy, polyester, polyamide, aramid polyamide, polyacrylic, polyethylene, ultra-high molecular weight polyethylene, polypropylene, cellulose, protein, elastomeric, polytetrafluoroethylene, polybenzoxazol (PBO), polyvinylcarbazole, polyetherketone, carbon, bamboo charcoal, glass, or other conductive or non-conductive materials. Thereby, the first single-strand yarn and each second single-strand yarn according to the invention can be composed of single-material fibers or mixed-material fibers, and not limited to high-performance fibers.

[0035] Similarly, in one embodiment, a single-strand of second multi-filaments is formed of the at least one material forming the N strands of first multi-filaments. A first fineness of the first single-strand yarn or each second single-strand yarn is identical to a second fineness of the single-strand of second multi-filaments. In particular, the first single-strand yarn and each second single-strand yarn both have a first strength, the single-strand of second multi-filaments has a second strength, and the first strength is equal to or greater than 70% of the second strength.

[0036] In one embodiment, a number of neps on a surface of the textile article according to the invention is equal to or less than 30/m.sup.2.

[0037] Compared to the prior art, within the single-strand yarn of the sampling length or each single-strand yarn of the plied yarn, which is equal to or less than 10 meters, the ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, where the sampling length is equal to or less than 10 meters. Moreover, the dispersion of the weight distribution in the average length of said one single-strand yarn is equal to or less than 60%. Therefore, the single-strand yarn and the plied yarn according to the invention having high strength and high diameter uniformity. Moreover, the textile article woven from the yarns made from the stretch-broken staple fibers according to the invention has better smoothness.

[0038] In one embodiment, the N strands of first multi-filaments according to the invention are formed of 316L stainless steel, and the textile article according to the invention is woven by a knitting process. The knitted textile article can be used as a separation cloth for covering molds and tempering or press-on rings which are utilized in the process of forming glass plates, or for covering the means of transport by which glass plates are moved during the forming process.

[0039] In an example, according to the invention, a double-strand of Kevlar® multi-filaments of 3000D is fed into a stretching machine to obtain a stretch-broken sliver, and then the stretch-broken sliver is fed to a spinning machine to be spun into a 30Ne single-yarn. The 30Ne single strand yarn is sampled at a sampling length of 1 meter. Within the single-strand yarn of the sampling length, the ratio of the number of staple fibers in the single-strand yarn, whose length equal to or greater than 60% of a setup fiber length of 65 mm, to the total number of the staple fibers is 60˜75%. The dispersion of the weight distribution of the average length of the yarn is controlled within 15˜25%. Compared to traditional yarns with a fineness equivalent to the fineness of the 30Ne single strand yarn of the example of the invention, a traditional 350D single-strand of Kevlar® multi-filaments has the strength of up to 10 kg. A traditional double-strand twisted yarn of 30Ne is made from a plurality of Kevlar® staple fibers, but its strength is only 3.6˜4 kg. The 30Ne single strand yarn of the example of the invention has the strength of 7.5˜8 kg. Obviously, the single-strand yarn and the plied yarn spun from staple fibers made by stretching and controlled breaking according to the invention have high strength and high diameter uniformity.

[0040] In another example, a double-strand yarn of 6.5Ne spun from a plurality of 316L stainless steel staple fibers made by stretching and controlled breaking according to the invention is woven into a knitted textile article. The knitted textile article can be used as a separation cloth for covering molds and tempering or press-on rings which are utilized in the process of forming glass plates, or for covering the means of transport by which glass plates are moved during the forming process. The 316L stainless steel double-strand yarn of 6.5Ne according to the invention is sampled at a sampling length of 1 meter. Within the double-strand yarn of the sampling length, the ratio of the number of staple fibers in the double-strand yarn, whose length equal to or greater than 60% of a setup fiber length of 65 mm, to the total number of the staple fibers is controlled within 65˜70%. The dispersion of the weight distribution of the average length of the yarn is controlled within 35˜45%. The number of neps or indurations on the surface of the knitted textile article in this example is measured to be less than 20 per square meter. Obviously, compared to the traditional textile article woven from the yarns made from the stretch-broken staple fibers of the prior art, the textile article woven from the yarns made from the stretch-broken staple fibers according to the invention has better smoothness.

[0041] From the above detailed description of the present invention, it can be clearly understood that the single-ply yarn according to the present invention or each ply yarn in the ply yarn itself is within a sampling length of not more than 10 meters, among multiple short fibers The ratio of the number of short fibers with a length equal to or greater than 60% of the set fiber length to the total number of multiple short fibers is equal to or greater than 60%, and the set fiber length is not less than 65 mm. In addition, the weight distribution dispersion of the average length of the single strand yarn is equal to or less than 60%. Therefore, according to the present invention, the single-ply yarn and the double-ply yarn have high strength and high diameter uniformity. In addition, textiles made from fibers formed into yarns and woven by the stretch-break method according to the present invention have better smoothness.

[0042] With the detailed description of the above preferred embodiments of the invention, it is clear to understand that within the single-strand yarn of the sampling length or each single-strand yarn of the plied yarn, the ratio of the number of the staple fibers, whose length is equal to or greater than 60% of a setup fiber length, to the total number of the staple fibers is equal to or greater than 60%, where the sampling length is equal to or less than 10 meters and the setup fiber length is equal to or larger than 65 mm. Moreover, the dispersion of the weight distribution in the average length of said one single-strand yarn is equal to or less than 60%. Therefore, the single-strand yarn and the plied yarn according to the invention have high strength and high diameter uniformity. Moreover, the textile article woven from the yarns made from the stretch-broken staple fibers according to the invention has better smoothness.

[0043] With the example and explanations above, the features and spirits of the invention will be hopefully well described. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teaching of the invention. Accordingly, the above disclosure should be construed as limited only by the meters and bounds of the appended claims.