Composite Alpaca yarn and process for making same

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Quick Facts

Patent No.: US 7,882,687
App. No.: 12/263,193
Granted: Feb 8, 2011
Kind: B2

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Abstract

Composite Alpaca yarn and a process for making same. The composite Alpaca yarn comprises special and unique characteristics created by blending long natural irregular Camelid fibers, such as Alpaca, with short synthetic fibers, or other natural fibers, in a combination determined by homogenization of fibers. The homogenization of fibers takes into account fiber lengths for twisting them with the use of high-pressure air blown nozzles, wherein Alpaca fiber is wrapped around an internal core. The face and surface of the composite Alpaca yarn, exhibit the fine characteristics of the Camelid fibers, including thermal isolation and impermeability, along with exceptional softness, wherein the Camelid fibers can be as fine as 18 microns.

Claims (40)

1. Composite Alpaca yarn, comprising Alpaca fibers wrapped around an internal core, said internal core is made primarily of synthetic fibers, said Alpaca fibers are from an Alpaca, and said synthetic fibers are made of micro fibers of polyester or cellulose, said Alpaca fibers make up an exterior face by covering up to approximately 20% of said internal core.

2. A process for making the composite Alpaca yarn set forth in claim 1 , comprising the following steps:

A) stretching Alpaca fibers having an Alpaca top count of approximately of 0.025 Ne;

B) breaking said Alpaca fibers from long lengths of approximately 70 millimeters to medium lengths of approximately 38 millimeters;

C) collecting said medium lengths of said Alpaca fibers with a suction nozzle into a single fiber deposit;

D) mixing said medium lengths of said Alpaca fibers with said synthetic fibers;

E) carding said medium lengths of said Alpaca fibers and said synthetic fibers;

F) drawing said medium lengths of said Alpaca fibers and said synthetic fibers a first pass after said carding;

G) drawing said medium lengths of said Alpaca fibers and said synthetic fibers a second pass after said first pass;

H) drawing said medium lengths of said Alpaca fibers and said synthetic fibers a third pass after said second pass;

I) spinning said medium lengths of said Alpaca fibers and said synthetic fibers; and

J) wrapping said medium lengths of said Alpaca fibers around said internal core.

3. The process for making the composite Alpaca yarn set forth in claim 2 , further characterized in that in said Step A) said stretching Alpaca fibers comprises drafting said Alpaca fibers 6 times, having a front roller distance of approximately 50 mm, having a back roller distance of approximately 54 mm, at a speed of approximately 280 meters per minute.

4. The process for making the composite Alpaca yarn set forth in claim 2 , further characterized in that in said Step B) said Alpaca fibers are broken from said long lengths to said medium lengths, whereby raw said Alpaca fibers, enters through said back rollers and is drafted at least 6 times.

5. The process for making the composite Alpaca yarn set forth in claim 2 , further characterized in that in said Step D) said mixing of said Alpaca fibers and said synthetic fibers occurs in a first machine.

6. The process for making the composite Alpaca yarn set forth in claim 5 , further characterized in that in said Step E) said carding of said Alpaca fibers and said synthetic fibers occurs with a second machine having settings of licker in speed approximately 808 RPM, main cylinder speed of approximately 350 RPM, flat speed of approximately 150 mm/min, for a production of approximately 110 meters per minute, having a final count of approximately 0.12 Ne, and said second machine adjusts automatically for a given sliver count.

7. The process for making the composite Alpaca yarn set forth in claim 6 , further characterized in that in said Step F) said drawing is done on standard cotton draw frames with a third machine having settings of back roller distance approximately 50 mm; front roller distance approximately 47 mm; placing 6 slivers of said medium lengths of said Alpaca fibers and said synthetic fibers together for them to be stretched; drafting said 6 slivers 6 times; having a speed of approximately 450 meters per minute; having a final count of approximately 0.12 Ne, and said third machine does not adjust automatically for a given sliver count.

8. The process for making the composite Alpaca yarn set forth in claim 7 , further characterized in that in said Step G) said drawing is done on said standard cotton draw frames with a fourth machine having settings of back roller distance approximately 48 mm; front roller distance approximately 45 mm; slivers together for them to be stretched; having a total draft of 6 drafting said 6 slivers 6 times; having a speed of approximately 450 meters per minute; having a final count of approximately 0.12 Ne, said fourth machine adjusts automatically for a given sliver count.

9. The process for making the composite Alpaca yarn set forth in claim 8 , further characterized in that in said Step H) said drawing is done on said standard cotton draw frames with a fifth machine having settings of back roller distance approximately 46 mm; front roller distance approximately 43 mm; placing 3 slivers of said medium lengths of said Alpaca fibers and said synthetic fibers together for them to be stretched; drafting said 3 slivers 6.5 times; having a speed of approximately 450 meters per minute; having a final count of approximately 0.26 Ne, and said fifth machine adjusts automatically for a given sliver count.

10. The process for making the composite Alpaca yarn set forth in claim 9 , further characterized in that in said Step I) said spinning is performed by air jet spinning to separate most of said Alpaca fibers from said synthetic fibers by centrifugal forces.

11. The process for making the composite Alpaca yarn set forth in claim 10 , further characterized in that in said Step J) said wrapping is performed by said air jet spinning to wrap said Alpaca fibers around said synthetic fibers to produce aid composite Alpaca yarn, whereby said air jet spinning mechanism comprises three drafting zones, and two air jet nozzles that are aligned in opposite directions.

12. The process for making the composite Alpaca yarn set forth in claim 11 , further characterized in that said air jet spinning is done with a sixth machine having settings of top rollers as back: approximately 43 mm; middle: approximately 43 mm; and front: approximately 48.5 mm, bottom rollers are set as back: approximately 45 mm; middle: approximately 41.5 mm; and front: approximately 44 mm, air pressures are set as Nozzle 1: 3.0 Kg/cm 2 ; and Nozzle 2: 5.5 Kg/cm 2 , a condenser is set at approximately 2 mm and drafting said composite Alpaca yarn approximately 196.3 times; and a Main Draft approximately 35.8 mm; Nozzle—Front Roller distance approximately 38.5 mm; Feed Ratio approximately 0.98; Speed approximately 247 meters per minute; and Final count approximately 50/1 Ne.

13. A process for making Composite Alpaca yarn comprising Alpaca fibers wrapped around an internal core, said internal core is made primarily of synthetic fibers, said Alpaca fibers make up an exterior face by covering up to approximately 20% of said internal core, comprising the following steps:

A) stretching Alpaca fibers having an Alpaca top count of approximately of 0.025 Ne, said stretching Alpaca fibers comprises drafting said Alpaca fibers 6 times, having a front roller distance of approximately 50 mm, having a back roller distance of approximately 54 mm, at a speed of approximately 280 meters per minute;

B) breaking said Alpaca fibers from long lengths of approximately 70 millimeters to medium lengths of approximately 38 millimeters, whereby said Alpaca fibers are broken from said long lengths to said medium lengths, whereby raw said Alpaca fibers, enters through said back rollers and is drafted at least 6 times;