FIELD OF TECHNOLOGY

This disclosure relates generally to textiles and, more particularly, to a method, a device and/or a system of a proliferated thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package.

BACKGROUND

A consumer textile, for example apparel or bed sheets, may possess several characteristics that make it desirable. One desirable characteristic may be comfort for fabrics that come in contact with human skin. Another desirable characteristic may be durability, as consumer textiles may be laundered in machine washers and dryers that may tend to shorten the useful lifespan of the textile. In commercial operations, machine laundering may occur more than in residential or small-scale settings, which may further shorten the lifespan of the textile.

For textiles that contact human skin (for example T-shirts, underwear, bed sheets, towels, pillowcases), one method to increase comfort may be to use cotton yarns. Cotton may have high absorbency and breathability. Cotton may also generally be known to have a good “feel” to consumers.

But cotton may not be robust when placed in an environment with heavy machine laundering. To increase durability while retaining the feel and absorbency of cotton, the cotton yarns may be woven in combination with synthetic fibers such as polyester. Cotton may be used as warp yarns, while synthetic yarns may be used as weft yarns.

Constructing the textile using yarns with a smaller denier may also increase comfort. Using these relatively fine yarns may yield a higher “thread count.” A thread count of a textile may be calculated by counting the total weft yarns and warp yarns in along two adjacent edges of a square of fabric that is one-inch by one-inch. The thread count may be a commonly recognized indication of the quality of the textile, and the thread count may also be a measure that consumers associate with tactile satisfaction and opulence.

However, fine synthetic weft yarns, such as polyester, may break when fed into a loom apparatus. Cotton-polyester hybrid weaves may therefore be limited to larger denier synthetic yarns that the loom may effectively use. Thus, the thread count, and its associated comfort and luxury, may be limited.

In an attempt to claim high thread counts, some textile manufacturers may twist two yarns together, such that they may be substantially associated, before using them as a single yarn in a weaving process. A twisted yarn may yield properties in the textile similar to the use of a large denier yarn. Manufactures of textiles with twisted yarns may include within the advertised “thread count” each strand within each twisted yarn, even though the textile may not feel of satisfactory quality once it has been removed from its packaging and handled by the consumer. The Federal Trade Commission has taken the position in an opinion letter that it considers the practice of including each yarn within a twisted yarn in the thread count as deceptive to consumers.

Because fine denier yarns may break in a loom apparatus, cotton-synthetic blends may be limited to low thread counts and thus relatively low quality and comfort.

SUMMARY

Disclosed are a method, a device and/or a system of proliferated thread count of a woven textile by simultaneous insertion within a single pick insertion event of a loom apparatus multiple adjacent parallel yarns drawn from a multi-pick yarn package.

In one aspect, a method includes drawing each of multiple synthetic yarns from a corresponding supply package to form an oriented yarn, twisting and detwisting filaments within the formed oriented yarn to provide texture thereto, to provide a low stability interlacing during weaving, and to intermingle the filaments comprising the formed oriented yarn, and applying a uniform air pressure to the formed oriented yarn to provide a counter-twist following the twisting and the detwisting of the filaments.

The method also includes forming a multi-pick yarn package based on winding all formed oriented yarns analogous to and including the formed oriented yarn onto a spool following the application of the uniform air pressure, with the all formed oriented yarns serving as weft yarns forming adjacent substantially parallel yarns wound together, and simultaneously inserting the weft yarns in a single pick insertion event of a pick insertion apparatus of a loom apparatus. Further, the method includes conveying, through the pick insertion apparatus, the simultaneously inserted weft yarns across a warp shed of the loom apparatus through a set of warp yarns, and interlacing, through a beat up motion of a reed apparatus of the loom apparatus, the set of warp yarns and the conveyed weft yarns to produce an incremental length of a woven textile fabric.

In another aspect, a method includes drawing each of multiple synthetic yarns from a corresponding supply package to form an oriented yarn, twisting and detwisting filaments within the formed oriented yarn to provide texture thereto, to provide a low stability interlacing during weaving, and to intermingle the filaments comprising the formed oriented yarn, and applying a uniform air pressure to the formed oriented yarn to provide a counter-twist following the twisting and the detwisting of the filaments.

The method also includes forming a multi-pick yarn package based on winding all formed oriented yarns analogous to and including the formed oriented yarn onto a spool following the application of the uniform air pressure, with the all formed oriented yarns serving as weft yarns forming adjacent substantially parallel yarns wound together, and simultaneously inserting the weft yarns in a single pick insertion event of a pick insertion apparatus of a loom apparatus. Further, the method includes conveying, through the pick insertion apparatus, the simultaneously inserted weft yarns across a warp shed of the loom apparatus through a set of warp yarns made of a cotton material and/or a cellulosic fiber material, and interlacing, through a beat up motion of a reed apparatus of the loom apparatus, the set of warp yarns and the conveyed weft yarns to produce an incremental length of a woven textile fabric.

In yet another aspect, a system includes multiple synthetic yarns, each of which is drawn from a corresponding supply package to form an oriented yarn, a friction twisting unit to twist and detwist filaments within the formed oriented yarn to provide texture thereto, to provide a low stability interlacing during weaving, and to intermingle the filaments comprising the formed oriented yarn, and an intermingling jet to apply a uniform air pressure to the formed oriented yarn to provide a counter-twist to the friction twisting unit.

The system also includes a wiper guide and a traverse guide to enable winding of all formed oriented yarns analogous to and including the formed oriented yarn onto a spool to form a multi-pick yarn package following the application of the uniform air pressure through the intermingling jet, with the all formed oriented yarns serving as weft yarns forming adjacent substantially parallel yarns wound together, and a loom apparatus. The loom apparatus includes a pick insertion apparatus to simultaneously insert the weft yarns in a single pick insertion event, a warp shed across which the pick insertion apparatus conveys the simultaneously inserted weft yarns through a set of warp yarns, and a reed apparatus to interlace, through a beat up motion of the reed apparatus, the set of warp yarns and the conveyed weft yarns to produce an incremental length of a woven textile fabric.

The methods and systems disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form of a non-transitory machine-readable medium embodying a set of instructions that, when executed by a machine, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from the accompanying drawings and from the detailed description that follows.

