Methods, processes, and apparatuses for producing dyed and welded substrates

Abstract

A welding process may be configured to convert a substrate comprised of short staple fibers into a welded substrate having significantly increased strength as compared to the raw substrate. When applied to a one-dimensional substrate, such as a yarn, the welding process may also reduce the diameter of the welded substrate compared to that of the raw substrate. Additionally, the welding process may be configured to impart superior color properties to the welded substrate compared to the color properties of the raw substrate, which superior color properties may be very pronounced when performing a welding process on a raw substrate comprised of colored and/or dyed recycled fibers.

1 . A welded cellulosic-based yarn wherein the effective yarn density is from 0.5 g/cc to 1.0 g/cc, and wherein a strength of said welded yarn is from 10 cN/tex to 15 cN/tex. 
     
     
         2 . The welded yarn according to  claim 1  wherein said welded yarn is further defined as having been produced from a raw substrate comprised of a short staple fiber yarn utilizing a welding process. 
     
     
         3 . The welded yarn according to  claim 2  wherein a welding process for producing said welded yarn is configured to use an ionic liquid-based process solvent. 
     
     
         4 . The welded yarn according to  claim 1  wherein said welded yarn is less than sixty-five percent (65%) by weight a cellulose I crystal structure. 
     
     
         5 . The welded yarn according to  claim 1  wherein said welded yarn is less than sixty percent (60%) by weight a cellulose I crystal structure. 
     
     
         6 . A method for making a welded yarn, said method comprising the steps of:
 a. providing a raw substrate, wherein said raw substrate is comprised of a short staple fiber yarn;   b. applying a process solvent to said substrate to create a process wetted substrate, wherein said process solvent is capable of swelling and mobilizing at least one polymer in said substrate;   c. controlling at least a temperature and a duration of time for which said process solvent interacts with said process wetted substrate; and,   d. removing at least a portion of said process solvent from said process wetted substrate.   
     
     
         7 . The method according to  claim 6  wherein said short staple fiber yarn is further defined as having an average staple fiber length of less than 1.00 inches. 
     
     
         8 . The method according to  claim 7  wherein said short staple fiber yarn is further defined as having a virgin fiber content of at least 5% by weight, wherein a remainder of said short staple fiber yarn is made from a short staple fiber. 
     
     
         9 . The method according to  claim 8  wherein said welded yarn exhibits a strength increase of at least twenty percent (20%) over said short staple fiber yarn. 
     
     
         10 . The method according to  claim 8  wherein said welded yarn exhibits a strength per cross-sectional area increase of at least fifty percent (50%) over said short staple fiber yarn. 
     
     
         11 . The method according to  claim 6  wherein said short staple fiber yarn is further defined as exhibiting a strength not greater than 8 cN/text. 
     
     
         12 . The method according to  claim 7  wherein said welded yarn is further defined as exhibiting a strength of at least 11 cN/tex. 
     
     
         13 . The method according to  claim 12  wherein said welded yarn is further defined as having a diameter that is at least fifty percent (50%) less than a diameter of said short staple fiber yarn. 
     
     
         14 . The method according to  claim 13  wherein said short staple fiber yarn is further defined as having a density of not more than 0.38 g/cc. 
     
     
         15 . The method according to  claim 14  wherein said welded yarn is further defined as having a density of at least 0.5 g/cc. 
     
     
         16 . The method according to  claim 7  wherein said short staple fiber yarn is further defined as having a short staple fiber content of at least 30% by weight, wherein a remainder of said short staple fiber yarn is made from a virgin fiber. 
     
     
         17 . The method according to  claim 16  wherein said virgin fiber is further defined as having a staple fiber length of at least 1.00 inches. 
     
     
         18 . The method according to  claim 17  wherein said welded yarn exhibits a strength increase of at least twenty percent (20%) over said short staple fiber yarn. 
     
     
         19 . The method according to  claim 18  wherein said method is further defined as utilizing a process solvent comprised of an ionic liquid. 
     
     
         20 . A welded yarn made from a combination of a natural virgin fiber and a natural garnetted fiber, wherein said welded yarn is made from a raw yarn substrate comprising:
 a. an amount of said natural virgin fiber in the range of zero percent (0%) to ninety percent (90%) by weight; and,   b. an amount of said garnetted fiber in the range of ten percent (10%) to one hundred percent (100%) by weight, said amount of said natural virgin fiber chemically welded together with said amount of natural garnetted fiber to produce said welded yarn.   
     
     
         21 . The welded yarn according to  claim 20  wherein a strength per cross-sectional area of said welded yarn is at least twenty percent (20%) greater than a strength per cross-sectional area of said raw yarn substrate. 
     
     
         22 . The welded yarn according to  claim 21  wherein a welding process for producing said welded yarn is configured to use an ionic liquid-based process solvent. 
     
     
         23 . The welded yarn according to  claim 20  wherein said welded yarn is less than sixty-five percent (65%) by weight a cellulose I crystal structure. 
     
     
         24 . The welded yarn according to  claim 20  wherein said welded yarn is less than sixty percent (60%) by weight a cellulose I crystal structure. 
     
     
         25 . A welded yarn made from a raw yarn substrate, wherein said raw yarn substrate is comprised of a natural virgin fiber and a natural garnetted fiber, wherein a strength of said raw yarn substrate is less than 8 cN/tex, wherein a strength of said welded yarn is at least 11 cN/tex, wherein a cross-sectional area of said welded yarn is at least fifty percent (50%) less than a diameter of said raw yarn substrate, and wherein an elongation at break of said welded yarn is at least three percent (3%). 
     
     
         26 . The welded yarn according to  claim 25  wherein said diameter of said welded yarn is between thirty percent (30%) and fifty percent (50%) said diameter of said raw yarn substrate. 
     
     
         27 . The welded yarn according to  claim 25  wherein said strength of said welded yarn is at least twenty percent (20%) greater than said strength of said raw yarn substrate. 
     
     
         28 . The welded yarn according to  claim 25  wherein a strength per cross-sectional area of said welded yarn is at least thirty percent (30%) greater than a strength per cross-sectional area of said raw yarn substrate. 
     
     
         29 . The welded yarn according to  claim 25  wherein said welded yarn is less than sixty-five percent (65%) by weight a cellulose I crystal structure. 
     
     
         30 . The welded yarn according to  claim 25  wherein said welded yarn is less than sixty percent (60%) by weight a cellulose I crystal structure.