Method for producing elastic bands with recycled materials

Abstract

A method of manufacturing woven based elastic band, said method comprising the steps of attaching at least one yarn reel to rear side of a weaving device, adjusting the attached yarn based on desired pattern and width of the elastic band; attaching a warp system to the weaving device such that threads from the yarn reels are brought up to mouth of the weaving device. The method further comprises parallelly passing threads of an elastic material to bring up to mouth of the weaving device. The method further comprises the step of attaching a weft system to the weaving device such that threads in the weft are brought to the mouth, for binding the warp yarn threads with the elastic threads to produce elastic bands with desired pattern.

We claim: 
     
         1 . A method ( 200 ) of manufacturing a recycled woven based elastic band ( 124 ), said method ( 200 ) comprising the steps of:
 attaching at least one yarn reel ( 102 ) to rear side of a weaving device ( 100 ), wherein the at least one yarn reel ( 102 ) is made of any or a combination of recycled polyester, cotton, polypropylene, and nylon polyamide yarn;   adjusting the at least one attached yarn ( 112 ) based on desired pattern and width of the elastic band ( 124 ), wherein the denier value of the yarn ( 112 ) ranges from 70 to 300D, and wherein the yarn ( 112 ) constitutes a minimum of 35% of the weight of the elastic band ( 124 );   attaching a warp system ( 120 ) to the weaving device ( 100 ) such that threads from the yarn reel ( 102 ) in the warp are passed one by one through a first set of needles, and brought up to mouth ( 110 - 1 ) of the weaving device ( 100 ) where the elastic band ( 124 ) is woven;   parallelly passing an elastic material ( 106 ) one by one so as to bring the elastic material ( 106 ) up to the mouth ( 110 ) of the weaving device ( 100 ), wherein the elastic material ( 106 ) is selected from any or a combination of rubber latex, natural latex thread, recycled synthetic elastic fibers, spandex, and spandex thread, wherein the elastic material ( 106 ) has a concentration of rubber solids ranging from 55% to 65%   attaching a weft system ( 118 ) to the weaving device ( 100 ) such that yarn ( 112 ) in the yarn reel in the weft are brought to the mouth ( 110 ) of the weaving device ( 100 ), wherein the weft yarn threads ( 112 ) are used for binding the warp yarn threads ( 104 ) with the elastic material ( 106 ); and   weaving, using the weaving device ( 100 ), based on the desired pattern ( 304 ) and width of the elastic band ( 124 ), the warp yarn threads ( 104 ) with the elastic material ( 106 ) and the weft yarn threads ( 112 ) at the mouth ( 110 ) of the weaving device ( 100 ) to yield the recycled woven based elastic band ( 124 ).   
     
     
         2 . The method as claimed in  claim 1 , wherein the weaving device ( 100 ) is a computer operated Jacquard weaving device. 
     
     
         3 . The method as claimed in  claim 2 , wherein the weaving device ( 100 ) has 2-10 heads based on the width and chassis structure of the device ( 100 ). 
     
     
         4 . The method as claimed in  claim 1 , wherein the step of weaving is undertaken by the device ( 100 ) at a speed of 800-1400 RPM. 
     
     
         5 . The method as claimed in  claim 1 , wherein the recycled woven based elastic band ( 124 ) has a width ranging from 5 mm to 150 mm, and a thickness ranging from 0.5 to 5 mm. 
     
     
         6 . The method as claimed in  claim 1 , wherein the recycled woven based elastic band ( 124 ) has an elongation at break of 120% to 200%. 
     
     
         7 . The method as claimed in  claim 1 , wherein the recycled woven based elastic band ( 124 ) has an tensile strength ranging from 5-30 N/mm 2 . 
     
     
         8 . An elastic band ( 124 ) to hold a bedding product ( 302 ), said band ( 124 ) being made of recycled woven yarn ( 112 ) that is weaved with an elastic material ( 106 ) using a weft and warp based narrow weaving device ( 100 ) using the method ( 200 ) as claimed in  claim 1 .