Process for creating spun yarn

Abstract

Input fibers to be used for the manufacture of textile components are cut to a proper length [ 113] . The fibers are metallized [ 115] with silver and copper. The metallized fibers are opened [ 121] and blended [ 123] with other fibers. The blended fibers are preferably opened again [ 125] . Then the blended fibers are oriented [ 127] and drawn [ 129] into a sliver. Roving [ 140] may be applied to the sliver to condense the fibers. The length of the fibers, the denier of the fibers, the amount of metal coating and composition of the metal coating are selected to provide an optimum amount of metal ion discharge to have the proper antimicrobial properties, while optimizing wound healing properties, and minimizing manufacturing costs.

1 . A method of manufacturing a textile matrix having improved anti-microbial properties comprising the steps of:
 a) preparing input fibers [ 110 ], the preparation includes the following substeps:
 i. providing input fibers [ 113 ] with a predetermined length range, and 
 ii. metallizing the input fibers [ 115 ]; 
   b) carding the metallized fibers [ 120 ] by the following sub-steps:
 i. opening the metallized fibers [ 121 ] to separate the individual fibers from each other, 
 ii. blending the metallized fibers [ 123 ] with other fibers, 
 iii. orienting the blended fibers [127] in generally the same direction to create a web, and 
   iv. cross-lapping the fibers [ 128 ] of the web.   
   
   
       2 . The method of  claim 1  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] generally within the range of ½-8 cm.   
   
   
       3 . The method of  claim 1  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] with an average fiber length of ¾-6 cm.   
   
   
       4 . The method of  claim 1  wherein the step of providing input fibers [113] with a predetermined length range comprises the step of.
 providing input fibers [ 113 ] with an average fiber length of 1-3 cm.   
   
   
       5 . The method of  claim 1  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] with an average fiber length of approximately 2 cm.   
   
   
       6 . The method of  claim 1  wherein the step of metallizing the input fibers [ 115 ] comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 3-75% silver to copper by weight.   
   
   
       7 . The method of  claim 1  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 9-60% silver to copper by weight.   
   
   
       8 . The method of  claim 1  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 12-30% silver to copper by weight.   
   
   
       9 . The method of  claim 1  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio of approximately 21% silver to copper by weight.   
   
   
       10 . The method of  claim 1  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with zinc.   
   
   
       11 . The method of  claim 1  wherein the step of blending the metallized fibers [ 123 ] with other fibers includes the step of blending the metallized fibers [ 123 ] with one or more types of fibers of the group consisting of:
 cotton fibers, cellulose fibers, polyester fibers, acrylic fibers and nylon fibers.   
   
   
       12 . The method of  claim 1  wherein the step of blending the metallized fibers [ 123 ] with other fibers includes the step of:
 blending the metallized fibers [ 123 ] with bio-absorbable materials intended to be dissolved within a living body.   
   
   
       13 . The method of  claim 1  wherein the step of blending the metallized fibers [ 123 ] with other fibers includes the step of:
 blending the metallized fibers [ 123 ] with other metallized fibers having a different metal composition.   
   
   
       14 . The method of  claim 11  wherein the bio-absorbable material is an alginate. 
   
   
       15 . The method of  claim 1  further comprising, after the substep of blending [ 123 ], the step of:
 opening the blended fibers [ 125 ].   
   
   
       16 . The method of  claim 1 , further comprising, after the step of carding [ 120 ], the step of:
 needle punching the web [ 130 ].   
   
   
       17 . A method of manufacturing textile components from an input fiber having improved anti-microbial properties comprising the steps of:
 a) preparing input fibers [ 110 ], the preparation includes the following substeps:
 i. providing input fibers [ 113 ] with a predetermined length range, and 
 ii. metallizing the input fibers [ 115 ]; 
   b) carding the metallized fibers [ 120 ] by the following sub-steps:   i. opening the metallized fibers [ 121 ] to separate the individual fibers from each other,
 ii. blending the metallized fibers [ 123 ] with other fibers, 
 iii. orienting the blended fibers [ 127 ] in generally the same direction to create a web, and 
 iv. drawing the web [ 129 ] to create a sliver having fibers with antimicrobial properties. 
   
   
   
       18 . The method of  claim 17  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] generally within the range of ½-8 cm.   
   
   
       19 . The method of  claim 17  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] with an average fiber length of ¾-6 cm.   
   
   
       20 . The method of  claim 17  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] with an average fiber length of 1-3 cm.   
   
   
       21 . The method of  claim 17  wherein the step of providing input fibers [ 113 ] with a predetermined length range comprises the step of:
 providing input fibers [ 113 ] with an average fiber length of approximately 2 cm.   
   
   
       22 . The method of  claim 17  wherein the step of metallizing the input fibers [ 115 ] comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 3-75% silver to copper by weight.   
   
   
       23 . The method of  claim 17  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 9-60% silver to copper by weight.   
   
   
       24 . The method of  claim 17  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio within the range of 12-30% silver to copper by weight.   
   
   
       25 . The method of  claim 17  wherein the step of metallizing [ 115 ] the input fibers comprising the step of:
 coating at least a portion of the input fibers with silver and copper at a ratio of approximately 21% silver to copper by weight.   
   
   
       26 . The method of  claim 17  wherein the step of preparing the fibers [ 110 ] comprises the step of:
 preparing the fibers [ 110 ] to have a denier per fiber in the range of 0.5-50 dpf.   
   
   
       27 . The method of  claim 17  wherein the step of preparing the fibers [ 110 ] comprises the step of:
 preparing the fibers [ 110 ] to have a denier per fiber in the range of 0.7-30 dpf.   
   
   
       28 . The method of  claim 17  wherein the step of preparing the fibers [ 110 ] comprises the step of:
 preparing the fibers [ 110 ] to have a denier per fiber in the range of 1-10 dpf.   
   
   
       29 . The method of  claim 17  wherein the step of preparing the fibers [ 110 ] comprises the step of:
 preparing the fibers [ 110 ] to have a denier per fiber is approximately 3 dpf.   
   
   
       30 . The method of  claim 17  wherein the step of blending [ 123 ] the metallized fibers with other fibers includes the step of blending [ 123 ] the metallized fibers with one or more types of fibers of the group consisting of:
 cotton fibers, cellulose fibers, polyester fibers, acrylic fibers and nylon fibers.   
   
   
       31 . The method of  claim 17 , further comprising, after the step of carding [ 120 ], the step of:
 roving [ 140 ] to further condense the fibers.   
   
   
       32 . The method of  claim 17 , further comprising, after the step of drawing [ 129 ] the web, the step of:
 spinning [ 150 ] the sliver into a yarn having antimicrobial properties.   
   
   
       33 . The method of  claim 17  wherein the textile matrix includes one of the group consisting of:
 antibiotics, antifungals, zinc coated fibers, and hormones.