Production process of circular and sustainable mixed yarns and mixed yarns obtained

Abstract

A production process of mixed yarns and mixed yarns obtained from circular and or sustainable and or biodegradable textiles within any textile industry and or adapted in the machines within spinning mills. This makes possible a very large combination of different types of textile yarn mixtures and a wide range of weights of mixed sustainable and or biodegradable yarns, to meet and create new demands for sustainable and circular textile products. The process described for injection of compressed air is the combination and mixing of sustainable and circular and or biodegradable continuous filament yarns with biodegradable, and sustainable natural and/or artificial spun yarns, bringing technology to the products in line with the sustainability of the environment. This makes possible a definitive solution in ocean contamination by synthetic fibers and prevents much of the artificial textile fibers from fabrics and clothes, which release their cut fibers during industrial and domestic washing.

Claims

1. A method of producing a biodegradable and recyclable mixed yarn, the method comprising: placing at least one continuous filament in a bobbin support; placing the at least one continuous filament through a pair of tensioners, each tensioner in said pair of tensioners comprised of two-spring-loaded washers regulated by wing nuts, wherein the wing nuts are automatically or manually rotated to create a tension in order to regulate the entrance tension of the continuous filament; conducting a natural or artificial spun yarn made by and coming from a spun yarn machine and the at least one continuous filament through at least one yarn guide in parallel to enter a collector, wherein said collector is an enclosure box that surrounds at least one compressed air injection nozzle; wherein an insert is placed in the at least one compressed air injector nozzle to create a plurality of interlaced points between said continuous filament and said spun yarn; and placing the at least one continuous filament and the natural or artificial spun yarn through the at least one compressed air injector nozzle to make points of interlacing between said continuous filament and said natural or artificial spun yarn to make a mixed yarn; wherein said at least one compressed air injector nozzle further removes loosely attached molecules and fibers from said at least one continuous filament and the natural or artificial spun yarn; wherein the molecules include oligomer molecules; wherein the collector captures the loosely attached molecules and fibers from said at least one continuous filament and the natural or artificial spun yarn; and wherein the mixed yarn is wound on at least one winding packing bobbin.

2. The method of claim 1 wherein the at least one continuous filament is made of a material selected from the group consisting of recycled polyethylene terephthalate, polyester, biodegradable lactic polyacid plastic, biodegradable polyamide, biodegradable lyocell, biodegradable rayon, microbial cellulose, polyhydroxyalkanoate (PHA), cow manure cellulose, mushroom mycelium, animal protein cellulose, vegetal and fruit protein cellulose.

3. The method of claim 2 wherein the at least one continuous filament is a multi-component filament made of at least two raw materials.

4. The method of claim 1 wherein the natural or artificial spun yarn made by and coming from a spun yarn machine comprises at least one biodegradable yarn selected from the group consisting of cotton, organic cotton, viscose, lyocell, linen, hemp, and fibers from renewable natural raw material sources.

5. The method of claim 1 wherein each continuous filament of the at least one continuous filament receives a tension based on the elongation of each continuous filament.

6. The method of claim 1 wherein the compressed air pressure inside the at least one compressed air injection nozzle is between 0.3 and 6 bar.

7. The method of claim 1 further comprising removing the collector after capturing the plurality of molecules and fibers from said continuous filament and the natural or artificial spun yarn in order to clean the collector and dispose the plurality of molecules and fibers in a container.

8. The method of claim 7 wherein the collector is removed whenever there is a change of the winding packing bobbin.

9. The method of claim 1 wherein the spun yarn machine is selected from the group consisting of a vortex machine, a ring spun machine, and an open-ended machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram showing a process of producing circular and sustainable mixed yarns adapted in a vortex machine.

(2) FIG. 2 is a schematic diagram showing a process of producing circular and sustainable mixed yarns adapted to a ring yarn (combed or carded) machine.

(3) FIG. 3 is a schematic diagram showing a process of producing circular and sustainable mixed yarns adapted in a packing bobbin machines near to vortex, rotor, and ring yarns process machines.

(4) FIG. 4 is a schematic diagram showing a process of producing circular and sustainable mixed yarns adapted in an open-ended machine.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

(5) Reference will now be made to non-limiting embodiments, examples of which are illustrated in the figures. FIG. 1-4 show the steps of producing Clean Ocean mixed yarns adapted in a vortex, rotor, ring spun, winding packing bobbin yarn by first placing the continuous filaments and/or the spun yarns in a number of bobbin supports to be mixed with the yarn from and during process of vortex, rotor, ring spun, packing bobbin machine 1. Then, placing the continuous filaments and/or the spun yarns through the tensioners 2, the yarn guides 3, the air injector nozzle 4, the collector 5 which includes a protector 11 attached, and the mixed yarn winding packing bobbin 6.

(6) The inventive process can be coupled to an existing machine in the spinning mills including conventional rotor and air vortex, open end, ring spun and in textile industries packing bobbin machine to produce a more durable mixed yarn with more circularity of all raw material and resistance to elongation which also can be 100% biodegradable, no pollution of synthetic cut fibers, and less pollution of spun yarn from natural and artificial fibers during normal use and washing clothes.

(7) In step (1), a number of continuous filaments are placed in the bobbin supports while other bobbin supports can have natural and or artificial spun yarns too, which can be adapted to conventional and non-conventional spinning machines, interconnected or not, and in a packing bobbin machine.

(8) FIG. 1 shows that in some embodiments, the inventive process is coupled to a vortex machine where silver 8 goes through drafting device 7, front roller nip 9, and vortex nozzle 10 before being mixed with a number of continuous filaments 21. Continuous filaments 21 are placed in a number of bobbin supports 20a-20d of a packing bobbin machine 1 while other bobbin supports can have natural and or artificial spun yarns.

(9) FIG. 2 shows that in some embodiments, the inventive process is coupled to a yarn clearing 14, ring spun bobbin 15 and a spindle container 16 in a ring yarn machine.

(10) The number of spun yarns and continuous filaments is determined based on the specific needs to form a mixed yarn. The process can use any filament numbers of synthetics yarn and or biodegradable yarn to mix with any kind of artificial or natural spun yarn that are going in the process rotor, air vortex, open end, ring spun and/or placed in the bobbin supports in a packing bobbin machine. However, at least one filament yarn, sustainable and circular and or biodegradable must be selected.

(11) The spun yarns of bobbin supports and or the spun yarn doing in the process of spinning rotor, air vortex, open end, ring spun, of step (1) are preferably selected from the group consisting of cotton from the Better Cotton Initiative (BCI), organic cotton, biodegradable viscose, biodegradable lyocell, and biodegradable linen, biodegradable hemp and any renewable biodegradable fiber raw material source of nature, which have higher returns of the raw material for reprocessing of clothing without contaminating the environment including landfills, and soil.

(12) The natural or artificial spun yarn is homogeneous fibers grouped, aligned, and twisted to form a yarn. Each natural and artificial spun yarn has its characteristics defined by the size of its fibers and raw material used. The larger the fiber, the greater its resistance to breakage and elongation, and the softer the touch.

(13) In addition, different machine processes such as vortex, open end, and ring spun also give different yarns in resistance, elongation, and touch.

(14) The continuous filaments of step (1) are preferably a virgin and/or recycled and/or semi-recycled polyethylene terephthalate, polyester, polyamide, biodegradable lactic polyacid plastic and or biodegradable polyamide and or biodegradable lyocell and/or biodegradable rayon, microbial cellulose, polyhydroxyalkanoate (PHA), cow manure cellulose, mushroom mycelium, animal Protein cellulose, vegetal and fruit Protein cellulose and any other biodegradable filament and circular filament.

(15) Additionally, the characteristics of the biodegradable and circular interlaced filament protects the fibers of the spun yarns from loosening. The natural and artificial spun yarn protects the biodegradable and/or circular filament from friction between the filaments. Thus, the process produces a more durable yarn and circular raw materials.

(16) In step (2), the yarns pass through the tensioners 2, which is composed of two spring-loaded washers manually regulated by a wing nut 2a. The specific tension of the tensioner applied at the moment of the passage of the yarn may vary according to the elongation of each yarn. After inserting the yarn into tensioner, the wing nut is rotated to create a friction pressure. (See Table 1). The yarn is then placed in yarn guide 3, before entering air injector nozzle 4, collector 5, and the mixed yarn winding packing bobbin 6.

(17) In some embodiments, air injector nozzle 4 is placed inside collector 5 to prevent the loosely attached filament molecules and fibers from spun yarn from breaking loose.

(18) TABLE-US-00001 TABLE 1 Material Degree of Rotation Natural and artificial spun yarn 360 Polyester 540 PLA and others filaments from 630 renewable raw material Polyamide 630 Polyamide biodegradable 675

(19) In some embodiments, an automatic yarn feeder tensioner is used for grouping yarns with different physical stretching characteristics given a push velocity and perfect continuo tension to produce a good bobbin tension yarn and good interlaced points on the mixed yarn, before entering the passage inside the air injection nozzle in parallel, making a perfect interlacing between the biodegradable filament and/or recycled synthetic filament and/or circular synthetic filament with the natural and/or artificial spun yarn. Tensioner variations can change the effect to the final mixed yarn in terms of volume, touch, interlaced points and the packing bobbin.

(20) Therefore, prior to any adjustments on a tensioner, a technical specification from each manufacturer regarding the resistance to breakage and its elongation must be obtained through a rupture test on a dynamometer with a minimum variation.

(21) In step (3), yarn guide 3 guides each yarn 30 from the bobbin and or the yarn from the spinning machine and packing bobbin machine, in parallel, to enter the injection nozzle in step (4).

(22) In step (4) the continuous filaments create points of physical interlace points connections with the natural and/or artificial spun yarn by consequence of the whirlwind of compressed air, preferably from 0.3 to 6 Bar, inside injector nozzle 4, which adds a streaky visual effect to the fabric for making clothes and allows for less points of interlacing.

(23) In some embodiments, inserts 22 made of porcelain, which may vary from more open or closed or oval or round orifice, are placed in injector nozzle 4, thus allowing different interlaced points on the yarn, keeping the points firm, durable, and with mixed blend variations, with these properties remaining even after fabric and garment manufacturing.

(24) The durability of clothes is tested through washing in labs with high prevention of microfiber shedding, because the continuous filament creates strong interlacing points. These firm points between the spun yarns and continuous filaments allow the spun fibers to remain firmly attached and consequently, the spun fibers protect the continuous filaments from excessive friction between the filaments. As a result, the clothes are more durable, circular and they do not contaminate the environment with synthetic cut fibers.

(25) In step (5), the most important of this process, a collector 5 of oligomers is placed. The main purpose of a collector is to collect oligomer molecules, which are generally loosely fixed and poorly washed molecules in the process of dyeing polyester or polyethylene terephthalate or other continuous filament molecules, described in step (1) and the spun yarn fibers described in step (1).

(26) All yarns used in textiles for clothing may be dyed using less water. Preferably use the yarn filaments dyed in their primary form before extrusion during resin phase.

(27) In addition, the combination of the mixed yarns is processed via compressed air to ensure adequate removal and disposal of the existing oligomer molecules and other molecules and fibers in the process. When passing the yarn through an air nozzle, the compressed air produces violent friction on the yarn where the chains of loosely attached filament molecules and fibers from spun yarn naturally break loose and can be released into the environment, most of the pollution of the synthetic cut fibers comes from the manufacture. Thus, the collector functions to capture these chains of loosely attached filament molecules and spun yarn fiber. It does not allow these fiber and molecules to scatter into air, soil, and water. At each stop of change of the mixed bobbin yarn, the collector could be removed for cleaning and disposing the filament molecules and fibers in a proper container if is necessary in the process.

(28) Further, depending on the setting to decrease pressure of compressed air inside the internal passage of the air nozzle, lower air pressure is possible to obtain fewer points of interlacing. It is also possible that fewer interlacing points will occur between the yarn per linear meter and, yielding a final visual differentiation of the mixed yarns, which leads to less energy consumption when generating compressed air in the production line.

(29) Therefore, the inventive process and product is sustainable and eco-friendly which replaces conventional process using intimate blended fiber by avoiding significant contamination of soil, air, and the ocean caused by cutting synthetic fibers from intimate blended fiber. Further, the process also reduces the risk to users with respiratory health issues.

(30) In step (6), the winding packing bobbin machine 6 could be interconnected or not to another machine manually or automatically in preparation of mixed yarn conical reel. The speed varies according to its machine model.

(31) In some embodiments, the mixed yarn winding packing bobbin 6 is coupled to a grove bakelite drum 12.

(32) As shown herein, a process to produce circular and sustainable and or biodegradable mixed yarns, which is eco-friendly by replacing intimate blended fiber of cut synthetic fibers are disclosed. In some embodiment, the process uses biodegradable continuous filament, circular and/or sustainable and/or recycled and/or virgin synthetic continuous filament. Based on the above and illustrated, the present invention deals with mixed yarns mixed by compressed air, which are used in machinery of the conventional and unconventional spinning process, whether or not interconnected to other machines or produced in winding packing bobbin machines near to the spinning process within the textile industries, with characteristics of novelty, inventive step and industrial application, fundamental for patenting, with claims described below.