Process and apparatus for producing digital yarns using metal filaments for info-communications and digital yarns produced by said process

• US 20090056300A1
• Filed: 01/04/2007
• Published: 03/05/2009
• Est. Priority Date: 02/17/2006
• Status: Active Grant

• Current Assignee: GAIA Healthcare, Inc.
• Original Assignee: korea institute of industrial technology
• Inventors: An, Jae Sang, Lee, Dae-Hoon, Chung, Gi-Soo
• Granted Patent: US 7,845,153 B2
• Time in Patent Office: Days
• US Class Current: 57/256
• CPC Class Codes: D02G 3/12 Threads containing metallic filaments or strips
• CPC Class Codes: D02G 3/38 Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn; D02G3/32 takes precedence; covering endless core threads with fibres by using open-end spinning techniques D01H4/00
• CPC Class Codes: D02G 3/441 Yarns or threads with antistatic, conductive or radiation-shielding properties electroconductive, anti-static or radiation-shielding filaments D01F1/09, D01F1/106; anti-static fabrics D03D15/533; conducting, insulating or anti-static layers for floor coverings D06N7/0042
• CPC Class Codes: Y10T 428/2931 Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]

Abstract

A process and apparatus of producing conductive yarns in use for info-communication and conductive yarns produced thereby, in which the conductive yarns are produced using metal filaments. The conductive yarns and the production process thereof can improve productivity and thus save production costs over conventional conductive yarns and the production processes thereof. The conductive yarns can be produced into fine yarns of minimized cross section and with various colors. Clothes made of the conductive yarns can perform an info-communication function without any breakage in a repeatedly bending part and be washed.

Claims

1. A process for producing conductive yarns for use in info-communication, the process comprising the steps of:

(i) feeding a plurality of metal filaments;

(ii) heating the plurality of metal filaments to soften the plurality of metal filaments;

(iii) drafting and cutting the plurality of metal filaments into a plurality of slivers having a predetermined length;

(iv) drawing and twisting the plurality of slivers into a yarn;

(v) winding the yarn on a bobbin;

(vi) coating the yarn with a waterproof material and an electromagnetic shielding material in a thin film while unwinding the yarn from the bobbin;

(vii) drying the yarn; and

(viii) covering the yarn with a textile yarn.

2. The process according to claim 1 further comprising the step of:

between the step (iii) and the step (iv), simultaneously doubling and drafting the plurality of slivers produced by the step (iii) to improve the evenness of the plurality of slivers.

3. The process according to claim 1 wherein the step (iii) is carried out together with a slip-preventing step to prevent slips in the plurality of filaments in the drafting.

4. The process according to claim 1 further comprising the step of:

permeating an additive liquid into the plurality of slivers and drying a residual of the additive liquid from a surface of the plurality of slivers before the step (iv).

5. The process according to claim 4 wherein the additive liquid contains a small amount of surface active agent therein.

6. The process according to claim 1 further comprising the step of:

repeating the steps (vi) and (vii) for three to five times in succession.

7. The process according to claim 1 wherein the textile yarn is a dried fiber.

8. The process according to claim 1 wherein the textile yarn is a natural fiber.

9. A conductive yarn for use in info-communication, the conductive yarn comprising:

a plurality of slivers wherein the plurality of slivers are drafted and cut from a plurality of metal filaments wherein the plurality of metal filaments are heated to soften the plurality of metal filaments wherein the plurality of slivers are drawn and twisted;

a first coating on the plurality of slivers wherein the first coating is a water proof material;

a second coating on the plurality of slivers wherein the second coating is an electromagnetic shielding material; and

a covering on the plurality of slivers wherein the covering is a textile yarn.

10. An apparatus for producing conductive yarns for use in info-communication, the apparatus comprising:

a feed roller for feeding a plurality of metal filaments;

a heater for heating the plurality of metal filaments to soften the plurality of metal filaments;

a plurality of stretching rollers for drafting and cutting the plurality of metal filaments into a plurality of slivers with a predetermined length;

a spinning frame for drawing and twisting the plurality of slivers into a yarn wherein the spinning frame has a back roller and a front roller;

a winder for winding the yarn;

a coater for coating the yarn with a waterproof material and an electromagnetic shielding material in a thin film while unwinding the yarn from a bobbin;

a drier for drying the yarn; and

a covering unit for covering the yarn with a textile yarn.

11. The apparatus according to claim 10 further comprising:

a drawing unit arranged between one of the plurality of stretching rollers and the spinning frame to perform doubling and drafting to enhance evenness of the plurality of slivers.

12. The apparatus according to claim 10 further comprising:

anti-slip rollers arranged at both sides of one of the plurality of stretching rollers, respectively, to prevent slips of the plurality of metal filaments during drafting of the plurality of metal filaments.

13. The apparatus according to claim 10 further comprising:

an additive liquid feeder arranged at a top portion of the back roller to permeate an additive liquid into the plurality of slivers and to dry a residual of the additive liquid from surfaces of the plurality of slivers.

14. A process for producing conductive yarns for use in info-communication, the process comprising the steps of:

(i′

) feeding a plurality of metal filaments;

(ii′

) heating the plurality of metal filaments to soften the plurality of metal filaments;

(iii′

) collecting the plurality of metal filaments;

(iv′

) twisting the plurality of metal filaments to produce a filament yarn;

(v′

) winding the filament yarn on a bobbin;

(vi′

) coating a waterproof material and an electromagnetic shielding material in a thin film on the filament yarn while unwinding the filament yarn from the bobbin;

(vii′

) drying the filament yarn; and

(viii′

) covering the filament yarn with a textile yarn.

15. The process according to claim 14 further comprising the step of:

repeating the steps (vi′

) and (vii′

) for three to five times in succession.

16. The process according to claim 14 wherein the textile yarn is a dried fiber.

17. The process according to claim 14 wherein the textile yarn is a synthetic fiber.

18. (canceled)

19. An apparatus for producing conductive yarns for use in info-communication, the apparatus comprising:

a feed roller for feeding a plurality of metal filaments;

a heater for heating the plurality of metal filaments to soften the plurality of metal filaments;

a collector for collecting the plurality of metal filaments;

a rotor for twisting the plurality of metal filaments into a filament yarn;

a winder for winding the filament yarn on a bobbin;

a coater for coating the filament yarn with a waterproof material and an electromagnetic shielding material in a thin film while unwinding the filament yarn from the bobbin;

a drier for drying the filament yarn; and

a covering unit 5 for covering the filament yarn with a textile yarn.