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

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.

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 of  claim 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 of  claim 1 , wherein the cooling plate is set to a temperature between 0° C. and 40° C. 
     
     
         4 . The method of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 8 , wherein the spandex core has a denier from 20 to 300. 
     
     
         10 . The method of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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 of  claim 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.