US20230056331A1

US20230056331A1 - Feeding method of a carding machine in order to obtain a blended yarn, yarn and fabric obtain with it

Info

Publication number: US20230056331A1
Application number: US17/797,527
Authority: US
Inventors: David Anthony Woodhouse; Richard Michael Lightowlers
Original assignee: Lightowlers Yarns Ltd; Moorbrook Textiles Ltd
Current assignee: Lightowlers Yarns Ltd; Moorbrook Textiles Ltd
Priority date: 2020-02-07
Filing date: 2021-02-05
Publication date: 2023-02-23
Also published as: EP3918118A1; GB2594681A; JP2023513551A; WO2021156635A1; GB2594681B; GB202211464D0; GB202001662D0; CN115244232A; GB2608025A

Abstract

A method of loading a carding machine for the manufacture of yarn. The method includes deriving a component load schedule with a plurality of discrete loading steps. The series of discrete loading steps comprise at least a first load amount and a second load amount, wherein the sum of the first load amount and the second load amount is a first overall load amount. The method includes loading a first amount of a first component equal to the first load amount of a discrete loading step, loading a second amount of a second component equal to the second load amount of the discrete loading step and repeating the steps of loading a first amount and loading a second amount for each of the discrete loading steps.

Description

FIELD OF THE INVENTION

This invention relates to methods for manufacturing yarn or fabric and particularly, but not exclusively, to methods relating to a carding process.

BACKGROUND TO THE INVENTION

Manufacture of yarn, as well as fabric made from such yarn, having a single set of properties or characteristics throughout the length thereof is known. When woven into a fabric, conventional yarns provide uniform appearance and properties to the resulting fabric.
Typically, to change the properties of a fabric, it is necessary to swap a yarn or thread partway through the weaving process. However, doing so may introduce visible changes to the fabric (e.g., without limitation, changes in texture, colour or pattern) which may be undesirable.
Further, it is known to make fabrics out of yarns that contain both animal fibres and synthetic materials. The synthetic material improves the strength of the yarn and reduces the risk of damage or breakage of the yarns during weaving. Subsequent to the weaving process, the synthetic material can be dissolved, leaving only the animal fibres. This enables manufacture of finer and more light-weight fabrics than would otherwise be possible due to the lack of strength of an unsupported thread.
The inventors have appreciated the shortcomings of the existing methods.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a method of loading a carding machine comprising:

- deriving a component load schedule comprising a plurality of discrete loading steps, wherein each of said discrete loading steps comprises at least a first load amount and a second load amount, and wherein the sum of the first load amount and the second load amount is a first overall load amount;
- loading a first amount of a first component equal to the first load amount of a discrete loading step;
- loading a second amount of a second component equal to the second load amount of the discrete loading step; and
- repeating the steps of loading a first amount and loading a second amount for each of the plurality of discrete loading steps.

The first overall load amount may have a constant value. In some examples, both of the first load amount and the second load amount may be constant for each of the plurality of discrete loading steps. In some examples, the first load amount may be varied in accordance with a pre-defined function between at least two discrete loading steps in the plurality of discrete loading steps. The first load amount may be varied linearly between the first loading step in the plurality of discrete loading steps and the last loading step in the plurality of discrete loading steps.
Each of the plurality of discrete loading steps may further comprise a third load amount, and the method may further comprise a step of:

- loading a third amount of a third component equal to the second load amount of the discrete loading step; and
- wherein the step of repeating further comprises repeating the step of loading a third amount for each of the plurality of discrete loading steps.

At least one of the first component or the second component may comprise a natural fibre material and a sacrificial fibre material in a first blend ratio. At least one of the first component, the second component or the third component may comprise a natural fibre material and a sacrificial fibre material in a first blend ratio. The first blend ratio may be in the range 70:30 to 30:70, optionally in the range 65:35 to 35:65, optionally in the range 60:40 to 40:60, optionally in the range 55:45 to 45:55. The first blend ratio may be 50:50
The sacrificial fibre material may comprise one of a water-soluble synthetic material or a cotton fibre material.
In some examples, the step of deriving a component load schedule may comprise:

- selecting at least a portion of a first previous component load schedule; and
- carrying out the derivation step based at least partially on the selected portion of the first previous component load schedule.

The step of deriving may further comprise:

- selecting at least a portion of a plurality of previous component load schedules; and
- carrying out the derivation step at least partially based on one or more of the selected plurality of portions.

In accordance with a second aspect of the invention, there is provided a method for creating a strand, the method comprising:

- loading at least a first component and a second component into a carding machine in accordance with a method as set out above;
- carding the at least first and second components to produce a first sliver; spinning the sliver into a first strand.

The loading step may comprise loading at least a first component, a second component and a third component into the carding machine in accordance with a method as set out above; and the carding step may comprise carding the at least first, second and third components to produce the first sliver. In some examples at least one of the first component, second component or third component comprises a water-soluble synthetic material.
In accordance with a third aspect of the invention, there is provided a strand created by a method as set out above.
In accordance with a fourth aspect of the invention, there is provided a method for creating a fabric, the method comprising:

- weaving a fabric from a first yarn comprising at least a first strand created by a method as set out above.

In accordance with a fifth aspect of the invention, there is provided a fabric created by a method as set out above.
In accordance with a sixth aspect of the invention, there is provided a method for creating a fabric, the method comprising:

- weaving a fabric from a first yarn comprising at least a first strand created by a method according to claim 16; and
- dissolving the water-soluble synthetic material.

In accordance with a seventh aspect of the invention, there is provided a fabric created by a method as set out above.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention will now be described, by way of example, with reference to the drawings, in which:

FIG. 1 shows schematically an implementation of a method in accordance with a first aspect of the present invention;

FIG. 2 illustrates the method steps of the method illustrated in FIG. 1 ;

FIG. 3 shows schematically an implementation of a method in accordance with a second aspect of the present invention;

FIG. 4 shows the method steps of the method illustrated in FIG. 3 ;

FIG. 5 illustrates a first exemplary load component schedule according to an aspect of the present invention;

FIG. 6 illustrates a second exemplary load component schedule according to an aspect of the present invention;

FIG. 7 shows a method in accordance with a third aspect of the present invention;

FIG. 8 illustrates a method in accordance with a fourth aspect of the present invention;

FIG. 9 shows a method in accordance with a fifth aspect of the present invention; and

FIG. 10 illustrates a method in accordance with a sixth aspect of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The carding process typically involves providing fibres to a carding machine, in which the fibres are disentangled, cleaned and mixed so that they can subsequently be spun into strands.
Various carding techniques are well known in the art and will therefore not be described in further detail. However, wherever necessary or relevant in the following, reference may be made to specific parts of the carding process.
A central aspect of the carding process is the loading step, whereby fibres (or other components) are loaded into the carding machine. Typically, fibres are loaded into the carding machine in batches and at specific intervals. When only a single colour is used, the loading frequency and amount is used to maintain a uniform amount of fibre per unit length, such as to maintain a uniform thickness of the strand after spinning.
In accordance with a first aspect of the invention, a method of loading a carding machine 100 will now be described with reference to FIGS. 1 and 2 .
In a first step 201, a component load schedule 102 comprising a plurality of discrete loading steps 104 is derived, wherein each of said discrete loading steps comprises a first load amount 106 and a second load amount 108, and wherein the sum of the first load amount and the second load amount is a first overall load amount 110.
The component load schedule may be derived in any suitable fashion. In some examples, the component load schedule is derived based on one or more intended characteristics or properties of a resulting sliver, thread, yarn or fabric. In some examples, the component load schedule is derived based on one or more properties or characteristics of one or more of the materials used. In some examples, the component load schedule is derived based on one or more properties or characteristics of the carding machine or other machines or devices used in one or more of the carding process, spinning process, weaving process or a combination of these processes.
The component load schedule may comprise any suitable or advantageous number of discrete loading steps. The number of discrete loading steps may, in some examples be dependent on an intended length of the finished yarn. The number of discrete loading steps may additionally be dependent on one or more of: intended loading frequency; intended overall load amount per loading step; or intended linear weight of the sliver, strand or yarn.
Unlike some conventional methods relating to the manufacture of single-component yarn, as well as individual processing steps thereof, the exemplary method comprises using a first component and a second component. This enables use of components with different characteristics or properties. Examples, of characteristics or properties include (but are not limited to): choice of material; blend of materials; colour; thickness of fibres; length of fibres; or elasticity of materials.
The first load amount and the second load amount may have any suitable values. In known methods, wherein a single component is used, the load amount and the load frequency influence the properties of the resulting carded material (also referred to as a sliver), which in turn affects the properties of the thread or strand after spinning. Typically, it is desirable to maintain a constant overall load amount and a fixed load frequency so as to ensure that the resulting thread or strand is consistent. Specifically, it is desirable to ensure that the linear density of a resulting thread or yarn is substantially constant throughout the length of the thread or yarn.
In an example, the sum of the first load amount and the second load amount in each of the discrete loading steps is a first overall load amount, and wherein the first overall load amount has a constant value. As described above, this ensures that the properties or characteristics of a resulting thread or strand is substantially consistent.
In some examples, both of the first load amount and the second load amount are constant for each of the plurality of discrete loading steps. In such examples, the resulting thread or yarn is one with a substantially unchanging set of characteristics throughout its length.
In some examples, the first load amount and the second load amount may be varied in a suitable manner. In specific examples, the first load amount and the second load amount are varied such that the first overall load amount has a constant value. In other examples, the first load amount is increased and the second load amount is decreased by an identical amount, so that the first overall load amount remains constant throughout. Purely for conciseness purposes, and unless otherwise specifically noted, when reference is made to the first load amount and variations thereof, it will be assumed that the second load amount is varied proportionally so as to ensure that the first overall load amount is substantially constant throughout.
In an example, the first load amount is varied in accordance with a pre-defined function between at least two discrete loading steps in the plurality of discrete loading steps. The first load amount may be varied in accordance with any suitable function. It will be appreciated that the specific function may be chosen in dependence on a desired or intended configuration a fabric or garment that is eventually fabricated from the results of the method. In some examples, the function is a monotone function (e.g., a monotonically increasing or monotonically decreasing). The function can be strictly monotone or a weakly monotone. In other examples, the function is non-monotone. In other examples, the function is periodic. In yet other examples, the function is non-periodic. Exemplary functions include, but are not limited to: sinusoidal, parabolic, logarithmic or exponential. In some examples, the variation in the first load amount and the second load amount is defined by a plurality of functions. In some examples, the variation in load amounts is not definable by any specific function. It will be appreciated that the choice of function or variation, as well as specific parameter and variable values for such a function, is dependent on the length of the resulting yarn, as well as the dimensions and intended properties of a fabric manufactured from such a yarn.
In a specific example, the first load amount is varied linearly between the first loading step in the plurality of discrete loading steps and the last loading step in the plurality of discrete loading steps. The first load amount is varied between a first value and a second value.
Any suitable first value can be used, and any suitable second value can be used. In some cases, it may be desirable or advantageous to transition completely from the first component to the second component over the length of the process. In such an instance, the first load amount may, at the first of the plurality of discrete loading steps, be substantially identical to the overall load amount (with the second load amount initially being substantially being zero). Similarly, the first load amount may, at the last of the plurality of discrete loading step, be substantially zero (and the second load amount be substantially identical to the overall load amount).
If expressed in percentages, at the first of the plurality of discrete loading steps, the first load amount may comprise 100% of the overall load amount and the second load amount may comprise 0% of the overall load amount. Similarly, at the last of the plurality of discrete loading steps, the first load amount may comprise 0% of the overall load amount and the second load amount may comprise 100% of the overall load amount.
In other cases, it may be desirable or advantageous to transition only partially between the components. In other terms, both the first component and the second component are used in all of the plurality of discrete loading steps. In one such example, at the first of the plurality of discrete loading steps, the first load amount comprises 75% of the overall load amount and the second load amount comprises 25% of the overall load amount. At the last of the plurality of discrete loading steps, the first load amount comprises 25% of the overall load amount and the second load amount comprises 75% of the overall load amount.
It will no doubt be appreciated that the above is purely for exemplary purposes, and that the first load amount may, in principle, be varied between any percentage or proportion of the overall load amount. Additionally, the first load amount and the second load amount may be varied in a non-monotonic fashion. In the above example, while the first load amount changes between 75% and 25% of the overall load amount between the first discrete loading step and the last discrete loading step, the first load amount could, for example, comprise 100% or 0% for one or more intermediate discrete loading steps.
In a second step 202, an amount of a first component 112 equal to the first load amount of a specific discrete loading step is loaded. The first component may be loaded in any suitable manner. It will be appreciated that a number of specific loading mechanisms or methodologies may be envisaged within the scope of the present disclosure. In some examples, the loading mechanism automatically loads appropriate amounts of material during the discrete loading steps. The loaded material may, e.g., be provided from a storage element or unit connected to the loading mechanism.
The first component may comprise any suitable material or blend of materials. In some examples, the first component comprises natural fibres or a blend of a plurality of types of natural fibres. In some examples, the first component comprises a sacrificial fibre material. In an example, the first component comprises a blend of natural fibres (or plurality of types of natural fibres) and a sacrificial fibre material. An example of this will be discussed in more detail in the following.
In a third step 203, an amount of a second component 114 equal to the second load amount of the specific discrete loading step is loaded. Similarly to the first component, the second component may be loaded in any suitable manner. It will be appreciated that a number of specific loading mechanisms or methodologies may be envisaged within the scope of the present disclosure. In an example, the second component is loaded in the same manner as the first component.
The second component may comprise any suitable material or blend of materials. In some examples, the second component comprises natural fibres or a blend of a plurality of types of natural fibres. In some examples, the second component comprises a sacrificial fibre material. In an example, the second component comprises a blend of natural fibres (or plurality of types of natural fibres) and a sacrificial fibre material. An example of this will be discussed in more detail in the following.
In a fourth step 204, the steps of loading a first amount and loading a second amount are repeated for each of the plurality of discrete loading steps. Typically, the above steps will be repeated a number of times corresponding to the number of discrete loading steps in the plurality of discrete loading steps.
As described above, the component load schedule may comprise any suitable number of discrete loading steps. The specific number of loading steps may be dependent on one or more of: one or more intended parameters or characteristics of an intended final product; the load frequency; or the overall load amount. Some or all of these parameters or characteristics may be functionally interrelated and/or dependent on one or more of the other parameters or characteristics. For example, it will be appreciated that a particular linear weight of a resulting sliver may be achieved using a number of load frequencies by suitably varying the overall load amount.
Typically, the overall load amount will be constant for each of the plurality of discrete loading steps. However, in some examples, the overall load amount is variable.
As described above, the exemplary method can be used with any combination of first and second components. However, in some instances, it may be useful or advantageous to add one or more additional components (e.g., a third component) to the process. Hence, the sliver will be comprised of three or more components, each of which may have a particular set of characteristics or properties. This can be used to create a variety of different effects or characteristics in the sliver, the resulting strand or yarn, or even in the resulting woven fabric.
In accordance with a second aspect of the present invention, an exemplary method of loading a carding machine 300 will now be described with reference to FIG. 3 and FIG. 4 . For purposes of conciseness and clarity, only features and elements that differ substantially from corresponding features and elements described above will be discussed in detail in the following.
In a first step 401, a component load schedule 302 comprising a plurality of discrete loading steps 304 is derived, wherein each of said discrete loadings steps comprises a first load amount 306, a second load amount 308 and a third load 309 amount, and wherein the sum of the first load amount, the second load amount and the third load amount is a first overall load amount 310.
Although only a first component, second component and third component are described in the present example, the exemplary method could, in principle, comprise any number of components. The specific choice of three components is purely for exemplary purposes and for ensuring clarity and conciseness in the discussion of the present method.
In a second step 402, an amount of a first component 312 equal to the first load amount of a specific discrete loading step is loaded. The first component may be loaded in any suitable manner. It will be appreciated that a number of specific loading mechanisms or methodologies may be envisaged within the scope of the present disclosure. In some examples, the loading mechanism automatically loads appropriate amounts of material during the discrete loading steps. The loaded material may, e.g., be provided from a storage element or unit connected to the loading mechanism.
In a third step 403, an amount of a second component 314 equal to the second load amount of the specific discrete loading step is loaded. Similarly to the first component, the second component may be loaded in any suitable manner. It will be appreciated that a number of specific loading mechanisms or methodologies may be envisaged within the scope of the present disclosure. In an example, the second component is loaded in the same manner as the first component.
In a fourth step 404, an amount of a third component 316 equal to the third load amount of the specific discrete loading step is loaded. Similarly to the first and second components, the third component may be loaded in any suitable manner. It will be appreciated that a number of specific loading mechanisms or methodologies may be envisaged within the scope of the present disclosure. In an example, the third component is loaded in the same manner as the first and second components.
Each of the first component, second component or third component may comprise any suitable material or blend of materials. In some examples, each of the first component, second component or third component comprises natural fibres or a blend of a plurality of types of natural fibres. In some examples, each of the first component, second component or third component comprises a sacrificial fibre material. In an example, each of the first component, second component or third component comprises a blend of natural fibres (or plurality of types of natural fibres) and a sacrificial fibre material. An example of this will be discussed in more detail in the following.
In some examples, the first component, second component and third component comprise substantially identical materials or blends of materials. In other examples, at least one of the first component, second component or third component comprises a material or blend of materials that is substantially different from at least one of the other components. In some examples, each of the first component, second component and third component comprises a unique material or blend of materials.
In a fifth step 405, the steps of loading a first amount and loading a second amount and loading a third amount are repeated for each of the plurality of discrete loading steps. Typically, the above steps will be repeated a number of times corresponding to the number of discrete loading steps in the plurality of discrete loading steps.
As discussed above, the overall load amount will typically be substantially constant throughout the loading process. However, it will be appreciated that, in some examples, the overall load amount of each of the discrete loading steps may be varied according to a suitable function or variation.
Further, each of the components (i.e., the first component, second component or third component) may be varied according to any specific function or functions between the first of the plurality of discrete loading steps and the last of the plurality of discrete loading steps of the component load schedule as derived in the first method step.
The specific variations may be determined by the effect or characteristics that are desired in the resulting sliver or woven fabric. Any suitable first value, second value or third value can be used. In some examples, it may be desirable or advantageous to transition completely from the first component to the second component, and subsequently to transition completely from the second component to the third component over the length of the process.
This is illustrated in FIG. 5 , which shows an exemplary schematic illustration of a load component schedule 502. In the present example, the load component schedule is for use with a first component, second component and third component. Purely for exemplary purposes, the load component schedule comprises 10 discrete loading steps.
In this example, the first load amount (denoted by the numeral ‘1’ in the exemplary load component schedule) is, at the first of the plurality of discrete loading steps, substantially identical to the overall load amount (the second load amount and the third load amount initially being substantially zero). At step number 5, the second load amount (denoted by the numeral ‘2’ in the exemplary load component schedule) is substantially identical to the overall load amount (the first load amount and the third load amount being substantially zero). At the last of the plurality of discrete loading steps, i.e., step number 10, the first load amount and the second load amount are substantially zero, whereas the third load amount (denoted by the numeral ‘3’ in the exemplary load component schedule) is substantially identical to the overall load amount.
If expressed in percentages, at the first of the plurality of discrete loading steps, the first load amount may comprise 100% of the overall load amount and the second load amount and the third load amount may comprise 0% of the overall load amount. Similarly, at step number 5, the second load amount may comprise 100% of the overall load amount, and the first load amount and the third load amount may comprise 0% of the overall load amount. At the last of the plurality of discrete loading steps, the first load amount and the second load amount may comprise 0% of the overall load amount, and the third load amount may comprise 100% of the overall load amount.
The above-described example is purely exemplary in nature, and is merely intended to illustrate one possible load component schedule comprising first, second and third components. As described above, it is possible to use any convenient, advantageous or otherwise relevant number of components.
In some examples, all three of the first, second and third components may be present simultaneously for at least some of the discrete loading steps. An example of this is illustrated in FIG. 6 . In the present example, the load component schedule 602 is for use with a first component, second component and third component. Purely for exemplary purposes, the load component schedule comprises 14 discrete loading steps.
In the present example, the first load amount (denoted by the numeral ‘1’ in the exemplary load component schedule) is, at the first of the plurality of discrete loading steps, substantially identical to the overall load amount (the second load amount and the third load amount initially being substantially zero). At steps number 7 and 8, all of the first component, second component (denoted by the numeral ‘2’ in the exemplary load component schedule) and third component (denoted by the numeral ‘3’ in the exemplary load component schedule) are present. In the present example, the second load amount is substantially identical to the sum of the first load amount and the third load amount. At the last of the plurality of discrete loading steps, i.e., step number 14, the first load amount and the second load amount are substantially zero, whereas the third load amount is substantially identical to the overall load amount.
In other examples, none of the components ever comprise 100% of the overall load amount. In other terms, there will always be at least two components present in any given discrete loading step. It will be appreciated that many variations may be envisaged within the scope of the present disclosure.
As discussed above, the first component, second component or third component may comprise any suitable material or blend of materials. In some examples, the one or more of the components comprise natural fibres or a blend of a plurality of types of natural fibres. In some examples, the one or more of the components comprise a synthetic fibre material. In some examples, the one or more of the components comprise a sacrificial fibre material. In an example, one or more of the components comprise a blend of natural fibres (or plurality of types of natural fibres) and a sacrificial fibre material.
Synthetic or sacrificial materials are sometimes used in order to improve one or more characteristics or properties of the final product of the exemplary process (and, by extension, the characteristics or properties of one or more of the resulting slivers, threads, yarns, or woven fabric). In an example, a synthetic material may be used to improve the strength of the material. In other examples, a sacrificial fibre material may be used to maintain the structural integrity of the material during manufacture. After the manufacturing process is completed, the sacrificial fibre material is removed, which results in a fabric that is finer or lighter-weight than could otherwise be achieved.
Any suitable synthetic or sacrificial fibre material may be used. In some examples, the sacrificial fibre material comprises a suitable water-soluble synthetic material, such as (without limitation) PVA (polyvinyl alcohol). In some examples, the synthetic material comprises (without limitation) Kuralon K-II™ or Solvron™. In other examples, the sacrificial fibre material comprises a cotton-based fibre that can be removed after manufacturing by a carbonisation process.
As the sacrificial fibre material will not be present in the final product, it is both desirable and advantageous for the amount of the sacrificial fibre material to be substantially constant within each of the components into which it is blended. Each of the first component, second component or third component may have a specific blend ratio of natural fibre material to sacrificial fibre material. In some examples, each of the blend ratios is substantially identical. In other examples, two or more of the blend ratios are substantially identical and different to the remaining blend ratio(s). In yet other examples, each of the blend ratios is substantially unique and different from each of the other blend ratios. In a specific example, at least one of the first component, second component or the third component comprises a natural fibre material and a sacrificial fibre material in a first blend ratio.
Each of the blend ratios may have any suitable range. In some examples, the blend ratios are in the range 70:30 to 30:70, optionally in the range 65:35 to 35:65, optionally in the range 60:40 to 40:60, optionally in the range 55:45 to 45:55. In an example, the first blend ratio is 50:50.
In the foregoing examples, a number of method steps have been described that describe a methodology for loading a carding machine for use in the production of a sliver. This exemplary methodology, as it will be appreciated, may be employed in isolation or in combination with additional method steps, e.g., as part of a larger sequence of methods. Purely by way of example, the above-described exemplary methodologies may be employed as part of a strand, yarn or fabric creation process.
As described above, the component load schedule may be derived in a suitable fashion. In some examples, the component load schedule is derived solely based on one or more intended characteristics or properties of a resulting sliver, thread, yarn or fabric as described above.
In such cases, each component load schedule is derived separately and completely from the initial premises or requirements. However, performing the derivation for each production batch can be time consuming, in particular under circumstances where a particular component load schedule is similar to a previously derived component load schedule. For example, two subsequent production batches may differ only minutely from each other (e.g., having only a single property or characteristic that differs). Hence, it may be advantageous to perform the derivation step, at least in part, on one or more archived, stored or otherwise pre-generated component load schedules.
An exemplary implementation of such a derivation step will now be discussed in accordance with an aspect of the present invention. It will be appreciated that this is purely for exemplary purposes, and that other specific exemplary implementations may be envisaged within the scope of the present disclosure.
In the present example, at least a portion of a first previously derived component load schedule is selected. The portion may be selected in any suitable fashion based on any suitable criteria.
In some examples, the selection step is carried out based on the similarity of a previous component load schedule with the intended component load schedule. The similarity may be evaluated in any one of a number of ways. For example, it could be that a similar number of components are used, or that one or more intended characteristics or parameters of the product (e.g., a sliver, strand, yarn or fabric) resulting from use of the previous component load schedule are similar to intended characteristics of a new intended product.
The selection step may in some examples include a sub-step of selecting one or more specific criteria for evaluation. This may be relevant if there are specific requirements that should be prioritised over others. For example, in some instances, a given product may be required to have a certain linear density, tensile strength, colour gradient or material composition (or any other suitable or relevant parameters). Previous component load schedules can be checked for compliance with the relevant criteria and priorities.
In a second step, the derivation step is carried out based at least partially on the selected portion of the previously derived component load schedule. The derivation step may be carried out in a suitable way and using a suitable derivation process or methodology. This includes, without limitation: reusing the selected portion of the previously derived component load schedule; or modifying the selected portion of the previously derived component load schedule.
Reusing a portion of a previously derived component load schedule may be possible, for example if the selected portion is found to have a particular advantage or benefit. Purely by way of example, it may be found that a particular function governing the variation of a first load amount and a second load amount results in a particularly beneficial, advantageous or successful sliver, thread, yarn or fabric.
In other situations, it may not be possible to directly reuse the selected portion of the previous component load schedule. However, it may be possible to directly modify the selected portion in a relevant or suitable manner. This could, for example be, if the new component load schedule is a minor variation of the previous component load schedule.
Under certain circumstances, it may be the case that there isn't any single previous component load schedule (or portion thereof) that can be suitably used in isolation. However, it is possible that an intended product (e.g., a sliver, strand, thread, yarn or fabric) may share one or more similarities with a plurality of previous products. In such a situation, it may be possible to select at least a portion of the corresponding plurality of previous component load schedules and to use these to derive the component load schedule.
In an example, the step of deriving further comprises: selecting at least a portion of a plurality of previous component load schedules; and carrying out the derivation step at least partially based on one or more of the selected plurality of portions. The selecting step may be performed in any suitable manner. In some examples, it is performed substantially as described above with reference to selecting a single portion of a previous component load schedule. Similarly, the carrying out of the derivation step may be performed in any suitable fashion, for example substantially as described above.
Purely by way of example, one of the previous component load schedules could utilise a first specific transition between a first and second components. Another previous component load schedule could, for example, utilise a second specific transition between a second and a third component. It could, in such an instance, be advantageous or otherwise desirable to create a sliver, strand, yarn or fabric with both of the specific transitions. Instead of performing the derivation step from the beginning, the previously generated component load schedules may at least partially be used to create the component load schedule.
It will, of course, be appreciated that a component load schedule could be derived based on any suitable number of previous component load schedules, and that the above example is purely for illustrative (rather than limiting) purposes.
In accordance with a further aspect of the invention, an exemplary strand creation method will now be described with reference to FIG. 7 . For purposes of conciseness and clarity, only features and elements that differ substantially from corresponding features and elements described above will be discussed in detail in the following.
In a first step 701, at least a first component and a second component are loaded into a carding machine in accordance with a method as substantially described in the preceding examples. In one example, the first component and the second component are loaded substantially as described with reference to FIG. 2 above.
In a second step 702, the at least first and second components are carded to produce a first sliver. It will be appreciated that a number of specific carding methodologies may be envisaged within the scope of the present disclosure.
However, purely for conciseness purposes, this step will not be elaborated upon further in the present disclosure.
In a third step 703, the sliver is spun into a first strand. The spinning step may be carried out in any suitable fashion. It will be appreciated that there are a number of specific methods for spinning strands that could be envisaged within the scope of the present disclosure by the skilled person, and which will not be reproduced here in detail.
The first strand may subsequently be used to weave a fabric, or it may be combined with other strands to manufacture a yarn, which in turn may be used to weave a fabric.
In accordance with a further aspect of the invention, an exemplary strand creation method will now be described with reference to FIG. 8 . For purposes of conciseness and clarity, only features and elements that differ substantially from corresponding features and elements described above will be discussed in detail in the following.
In a first step 801, at least a first component, a second component and a third component are loaded into a carding machine in accordance with a method as substantially described in the at least one of the preceding examples (e.g., as substantially described with reference to FIG. 3 and FIG. 4 above).
As described above, the first component, second component and third component may comprise any suitable materials. In an example, at least one of the first component, second component or third component comprise a natural fibre material and a water-soluble synthetic material (as, for example, described with reference to FIG. 3 and FIG. 4 above).
In a second step 802, the at least first component, second component and third component are carded to produce a first sliver. It will be appreciated that a number of specific carding methodologies may be envisaged within the scope of the present disclosure.
In a third step 803, the sliver is spun into a first strand. The spinning step may be carried out in any suitable fashion. It will be appreciated that there are a number of specific methods for spinning strands that would be known to the skilled person, and which will not be reproduced here in detail.
The first strand may subsequently be used to weave a fabric, or it may be combined with other strands to manufacture a yarn, which in turn may be used to weave a fabric.
In accordance with a further aspect of the invention, an exemplary fabric creation method will now be described with reference to FIG. 9 . For purposes of conciseness and clarity, only features and elements that differ substantially from corresponding features and elements described above will be discussed in detail in the following.
In a first step 901, at least a first yarn is provided, the first yarn comprising at least a first strand created by a method as described above. In an example, the first strand has been created by a method substantially identical to that described with reference to FIG. 5 above.
In a second step 902, a fabric is woven from at least the first yarn. The fabric may be woven in any suitable manner and using a suitable loom or other similar device.
In accordance with a further aspect of the invention, an exemplary fabric creation method will now be described with reference to FIG. 10 . For purposes of conciseness and clarity, only features and elements that differ substantially from corresponding features and elements described above will be discussed in detail in the following.
In a first step 1001, at least a first yarn is provided, the first yarn comprising at least a first strand created by a method as described above. In an example, the first strand has been created by a method substantially identical to that described with reference to FIG. 6 above.
In a second step 1002, a fabric is woven from at least the first yarn. The fabric may be woven in any suitable manner and using a suitable loom or other similar device.
In an example, the first yarn is comprised of at least a first strand, wherein the first strand comprises a first component, second component and a third component. In this specific example, the third component comprises a water-soluble synthetic material. Any suitable synthetic material may be used. In some examples, the third component is comprised of a suitable water-soluble synthetic material, such as (without limitation) PVA (polyvinyl alcohol). In some examples, the synthetic material comprises (without limitation) Kuralon K-II™ or Solvron™
In a third step 1003, the water-soluble synthetic material is dissolved. This step may be performed in any suitable fashion. It will be recognised that a number of specific dissolution steps may be implemented within the scope of the present disclosures. In particular, it will be appreciated that the specific nature of the dissolution step may be dependent on the specific characteristics or properties of the water-soluble synthetic material.
The descriptions above are intended to be illustrative, not limiting. Thus, it will be apparent to one skilled in the art that modifications may be made to the invention as described without departing from the scope of the claims set out below.

Claims

1. A method of loading a carding machine comprising:

deriving a component load schedule comprising a plurality of discrete loading steps, wherein each of said discrete loading steps comprises at least a first load amount and a second load amount, and wherein the sum of the first load amount and the second load amount is a first overall load amount;

loading a first amount of a first component equal to the first load amount of a discrete loading step;

loading a second amount of a second component equal to the second load amount of the discrete loading step;

repeating the steps of loading a first amount and loading a second amount for each of the plurality of discrete loading steps; and

wherein the first load amount is varied in accordance with a pre-defined function between at least two discrete loading steps in the plurality of discrete loading steps.

2. A method according to claim 1, wherein the first overall load amount has a constant value.

3. A method according to claim 1, wherein the pre-defined function is a monotone function.

4. A method according to claim 1, wherein the pre-defined function is a linear function.

5. A method according to claim 4, wherein the first load amount is varied linearly between the first loading step in the plurality of discrete loading steps and the last loading step in the plurality of discrete loading steps.

6. A method according to claim 1, wherein each of the plurality of discrete loading steps further comprises a third load amount, the method further comprising a step of:

loading a third amount of a third component equal to the third load amount of the discrete loading step; and

wherein the step of repeating further comprises repeating the step of loading a third amount for each of the plurality of discrete loading steps.

7. A method according to claim 1, wherein the at least one of the first component or the second component comprises a natural fibre material and a sacrificial fibre material in a first blend ratio.

8. A method according to claim 6, wherein the at least one of the first component, the second component or the third component comprises a natural fibre material and a sacrificial fibre material in a first blend ratio.

9. A method according to claim 7, wherein the first blend ratio is in the range 70:30 to 30:70, optionally in the range 65:35 to 35:65, optionally in the range 60:40 to 40:60, optionally in the range 55:45 to 45:55, optionally 50:50.

10. (canceled)

11. A method according to claim 7, wherein the sacrificial fibre material comprises one of a water-soluble synthetic material or a cotton fibre material.

12. A method according to claim 1, wherein the step of deriving a component load schedule comprises

selecting at least a portion of a first previous component load schedule; and

carrying out the derivation step based at least partially on the selected portion of the first previous component load schedule.

13. A method according to claim 12, further comprising:

selecting at least a portion of a plurality of previous component load schedules; and

carrying out the derivation step at least partially based on one or more of the selected plurality of portions.

14. A method for creating a strand, the method comprising:

loading at least a first component and a second component into a carding machine in accordance with a method according to claim 1;

carding the at least first and second components to produce a first sliver;

spinning the sliver into a first strand.

15. A method according to claim 14, wherein:

the loading step comprises loading at least a first component, a second component and a third component into the carding machine in accordance with the method according to claim 6; and

the carding step comprises carding the at least first, second and third components to produce the first sliver.

16. A method according to claim 14, wherein the at least one of the first component, second component or third component comprises a water-soluble synthetic material.

17. A strand created by a method according to claim 14.

18. A method for creating a fabric, the method comprising:

weaving a fabric from a first yarn comprising at least a first strand created by a method according to claim 14.

19. A fabric created by a method according to claim 18.

20. A method for creating a fabric, the method comprising:

weaving a fabric from a first yarn comprising at least a first strand created by a method according to claim 15; and

dissolving the water-soluble synthetic material.

21. A fabric created by a method according to claim 20.

22. A yarn having at least one material property that varies along at least a portion of the length of the first yarn in accordance with a pre-defined function, wherein the at least one material property includes at least one of: choice of material; blend of materials; colour; thickness of fibres; length of fibres; or elasticity of materials.

23. The yarn of claim 22, wherein the at least one material property varies monotonically or linearly along at least a portion of the length of the yarn.

24. The yarn of claim 23, wherein the colour of the yarn varies monotonically or linearly along at least a portion of the length of the yarn.

25. The yarn of claim 22, wherein the at least one material property varies along substantially all of the length of the yarn.

26. A fabric comprising the yarn of claim 22.

27. A fabric woven from at least a first yarn, the first yarn being according to claim 22.