The present invention relates to a process for obtaining a spinnable and/or needlable Kapok fibre fraction, and/or Kapok fibre blend with one or more other fibres in a range of from 100% to 10% by weight, comprising the steps of: •a. sorting the longest and cleanest fibres for spinning, by subjectin
The present invention relates to a process for obtaining a spinnable and/or needlable Kapok fibre fraction, and/or Kapok fibre blend with one or more other fibres in a range of from 100% to 10% by weight, comprising the steps of: •a. sorting the longest and cleanest fibres for spinning, by subjecting the fibres to an air stream directed towards a deposition area with a sorting wall, whereby a longer fibre fraction is collected behind the sorting wall, to obtain a short staple Kapok fibre base having an average length of from 10 to 20 mm; •b. adjusting the average moisture content of the kapok fibre base to an average measured moisture content in the range of from 8% to 12% moisture, to obtain moisture- and length-adjusted Kapok fibres, and, optionally •c. blending the moisture-and length-adjusted Kapok fibres with the second fibre base, to obtain a Kapok-comprising fibre blend.
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1. A process for obtaining a spinnable and/or needable Kapok fibre fraction, and/or Kapok fibre blend with one or more other fibres in a range of from 100% to 5% by weight, the process comprising the steps of: a. sorting the longest and cleanest kapok fibres for spinning, which comprises volatizing
1. A process for obtaining a spinnable and/or needable Kapok fibre fraction, and/or Kapok fibre blend with one or more other fibres in a range of from 100% to 5% by weight, the process comprising the steps of: a. sorting the longest and cleanest kapok fibres for spinning, which comprises volatizing opened and unsorted Kapok fibres by subjecting them to an air stream, whereby the fibre-containing air stream is directed towards a deposition area comprising a sorting wall, whereby fibres of different lengths are deposited in the deposition area and/or against the sorting wall at a position commensurate with their length, weight and the resulting respective flight time, whereby a longer fibre fraction is collected behind the sorting wall, to obtain a short staple Kapok fibre base having an average length of at least 10 mm; andb. adjusting the average moisture content of the kapok fibre base to an average measured moisture content in the range of from 8% to 12% moisture, to obtain moisture- and length-adjusted Kapok fibres. 2. The process according to claim 1, wherein the sorting wall is based at an angle essentially perpendicular to the air stream, and at a distance and with a height suitable to obtain a kapok fibre fraction comprising fibres of at least 10 mm length. 3. The process according to claim 1, further comprising the steps of: teasing and/or carding the moisture- and length-adjusted Kapok fibres, or the Kapok-comprising fibre blend, to obtain Kapok-comprising carded fibres; andspinning the carded fibres, or roving the carded fibres and spinning the rovings, into a yarn. 4. The process according to claim 1, further comprising: drafting a roving of the kapok-comprising fibre blend to a thinner fibre strand; andwinding the strand, or twisting the strand to provide a twisted strand and winding the twisted strand, as a yarn to a wound yarn bobbin. 5. The process according to claim 1, wherein the one or more fibres comprise i) one or more of treated or untreated naturally occurring fibres, ii) one or more synthetic fibres, or iii) one or more synthetic fibres obtained by extrusion spinning, wet spinning, and/or melt spinning. 6. The process according to claim 1, wherein the one or more naturally occurring fibres are obtained from animal sources, such as wool from sheep, goat, alpaca, and/or rabbit, silk threads from silkworms, or from plant sources, such as cotton, flax, hemp, jute, sisal, milkweed or the like, wherein the one or more fibres are present preferably in an amount of from 0 to 85% by weight. 7. The process according to claim 1, wherein the one or more synthetic fibres include polyamides nylon; polyacrylic fibres, polyolefinic fibres and/or polyester fibres; cellulosic fibres: rayon; or lyocell; wherein the one or more fibres are present preferably in an amount of from 0 to 85% by weight. 8. The process according to claim 5, wherein the polyester fibres comprise aliphatic, semi-aromatic or aromatic polyester materials as virgin materials, recycled materials, or combinations thereof. 9. The process according to claim 1, further comprising sizing the fibre strand or yarn with a sizing agent, preferably wherein the sizing agent comprises a wax. 10. The process according to claim 9, wherein the sizing comprises contacting the fibre strand or yarn with a solid natural wax. 11. The process according to claim 1, wherein spinning includes one or more of: core-spun spinning; vortex spinning; wool spinning; worsted spinning; ring spinning; open end spinning; multi-component spinning; such as siro spinning; compact spinning; friction twisting; self-twist spinning; electrostatic spinning; twistless spinning. 12. The process according to claim 1, wherein a yarn is obtained having a Cotton Count (Ne) of from 6 s to 60 s. 13. The process according to claim 12, wherein the content of Kapok fibres in yarns with a cotton count ranging of from 6s to 21s (Ne) is in the range of from 20% to above and including 30%. 14. The process according to claim 13, wherein the content of Kapok fibres for ring spun, siro-compact, and/or core spun yarns is above 18%, and for open end spun yarns is above 31%. 15. The process according to claim 12, wherein the content of Kapok fibres in yarns with a cotton count ranging of from 23s to 60s (Ne) is in the range of from 10% to 30%. 16. The process according to claim 15, wherein the content of Kapok fibres for ring spun, siro-compact, and/or core spun yarns is above 15%, and for open end spun yarns is above 30%. 17. The process according to claim 12, wherein the content of Kapok fibres in yarns with a cotton count ranging of from 35s to 60s (Ne) is in the range of from 15% to 25%. 18. The process according to claim 1, further comprising a step to convert the yarn into a woven or non-woven fabric. 19. A yarn comprising 50% by weight or more of Kapok fibres obtained according to claim 1, the yarn having a Count-related yarn tenacity of above 7, and a Single Yarn Strength and Elongation with CV % pursuant to as determined by ASTM D2256 of above 5.95. 20. The yarn according to claim 19, further comprising at least a second and/or third fibre. 21. A fabric comprising the yarn according to claim 19. 22. The process according to claim 1, further comprising a step to convert the moisture- and length-adjusted Kapok fibres, or the Kapok-comprising fibre blend into a batt, needling the batt of blended fibres, and subjecting the needled batt of fibres with a suitable sizing, and/or placing the needled batt into a scrim. 23. The process according to claim 1, further comprising a step to convert the moisture- and length-adjusted Kapok fibres, or the Kapok-comprising fibre blend into a batt, cross-lapping (layering) the batt of blended fibres and subjecting the cross-lapped batt of fibres with a suitable sizing, and/or placing the needled batt into a scrim. 24. The process according to claim 22, further comprising adding low melt fusible fibres to the moisture and length adapted Kapok fibres, forming the blend into a batt, needling the batt of blended fibres, subjecting the needled batt of fibres to a temperature above the melting temperature of the low melt fusible fibres for a period of time sufficient to form a cohesive composite non-woven fabric, and treating the composite non-woven fabric during a cooling down step to provide flexibility. 25. A non-woven material obtained according to claim 22. 26. A shaped article comprising a fabric according to claim 21. 27. The use of a spinnable and/or needable Kapok fibre fraction, and/or Kapok fibre blend with one or more other fibres in a range of from 100% to 15% by weight for the preparation of yarns, woven and non-woven fabrics or insulation materials. 28. The process of claim 1, further comprising blending the moisture-and length-adjusted Kapok fibres with a second or further fibre base, to obtain a Kapok-comprising fibre blend.
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