EP1270778A1 - Process and apparatus for producing staple-yarns which contain synthetic fibres - Google Patents

Abstract

In a process to make thread from staple fibre, the fibres are compacted at random into strips (12) and doubled to yarn (13). The yarn is especially stretched and optionally fixed. <??>A process produces yarn (13) from a synthetic or natural polymer staple fibre from which continuous filaments (10) are made in a primary spinning stage. The filaments are collected at random and compacted to form a spun-bonded fabric (11) which is longitudinally separated into a number of strips (12). Each strip is doubled into yarn (13) prior to stretching and optional fixing. The interconnected continuous filaments (10) are converted into interconnected staple fibres which are orientated in the longitudinal direction and stretched. The molecular structure produced by stretching is fixed in the fibres. The process facilitates the production of yarn which is similar to that produced by direct spun stretched cables. <??>An Independent claim is also included for a commensurate textile manufacturing assembly.

Description

The invention is in the field of spinning technology and relates to a method and a device according to the preambles of the corresponding independent Claims. The method and device are used to manufacture Staple fiber yarns that consist at least partially of man-made fibers, i.e. from Staple fibers made from synthetic or chemical-technical processes natural polymers are made.

According to the state of the art are used for the production of yarns Staple fibers, e.g. from cotton or wool fibers spinning processes used in which a roving or a ribbon is refined by stretching and then one Yarn formation by twisting or other suitable consolidation (e.g. swirling or gluing the fibers). That of yarn formation previous refinement can also be called opening by dissolving one Fiber association can be achieved. The fiber material fed to the spinning process becomes previously usually removed from bales, cleaned and / or if necessary mixed and in preparation steps depending on the fiber material (carding, Combing, stretching, etc.) into one for a specific spinning process and for one specific end product brought into a suitable form, usually in a form in which the fibers only adhere to one another by adhesive or frictional forces and already have a preferred, parallel orientation in the longitudinal direction.

If the staple fiber material is man-made fibers, the fiber bales manufactured by, for example, in a primary spinning process Extrusion from spinnerets creates quasi endless filaments that this Filaments for aligning the macromolecules stretched and fixed and in a variety can be combined into a cable that can be cut out of the cable or tearing (converting) flakes of staple fibers and that these flakes are pressed into bales. The further treatment of the fiber material then essentially corresponds to the sequence of pretreatment outlined above, Refinement and yarn formation.

The staple fibers created in this way are dependent on the manner in which the cables are cut all substantially the same length (rectangular stacking diagram) or similar to natural fibers in a range varying lengths.

The above briefly outlined yarn production process for man-made fibers Leading fiber bales is very expensive. But it has the advantage that the Chemical fiber bales are processed in essentially the same way can like natural fiber bales. In other words, the two types of bales can be processed with the same spinning preparation machines. It can therefore in essentially the same spinning processes of staple fiber bales starting yarns from man-made fibers, from natural fibers and in particular also from Mixtures of the two types of fibers can be produced.

A simpler method for producing staple fiber yarns from man-made fibers is the so-called direct spinning. According to this procedure, the in a primary spinning process by, for example, extrusion and stretching produced, almost endless filaments in a variety to a cable summarized. The cable is fed to a device in which the filaments torn or cut and the resulting fiber structure by stretching is refined. The resulting longitudinal fiber structure is then used directly for yarn formation fed. Such methods have over those mentioned above Processes using fiber bales have the advantage that they are significantly simpler. The parallel arrangement of the filaments in the cables is during the conversion in maintained essentially, that is, by converting the filaments The resulting staple fibers hardly need to be parallelized for yarn formation become. The stack length and the stack length distribution are in direct spinning depending on the setting and / or configuration of the for the length reduction of Filaments and the device used to refine the fiber structure (Converter).

While the yarn formation in a direct spinning process is essentially the same can, like in a spinning process that starts from fiber bales, is that of Yarn formation upstream refinement, which also reduces the length of the filaments has to contain, to design differently. The direct spinning process therefore needs compared to conventional spinning processes for the production of yarn Staple fibers specially equipped spinning machines. It also shows that in Yarns produced by direct spinning tend to fluctuate periodically and cannot meet the highest quality requirements. Direct spinning process also do not allow easy production of blended yarns, that is, for example of yarns made from a mixture of man-made fibers and natural staple fibers consist.

It is now the object of the invention to provide a method and a device for producing staple fiber yarns which at least partially consist of man-made fibers. The method and device according to the invention should be simple and nevertheless suitable for the production of high quality yarns. The method and device according to the invention are also intended to allow yarns to be produced from staple fiber mixtures, in particular from mixtures of natural and man-made fibers, without complex adjustments.
This object is achieved by the method and the device as defined in the patent claims.

According to the inventive method in a primary spinning process generated filaments stored in a flat storage. This flat filing is then consolidated into a spun bond. The spunbond is then the Cut lengthways into a plurality of spunbonded tapes, passing through them Separation, the quasi endless filaments are reduced in length, that is Staple fibers are created. A spunbonded nonwoven tape becomes a spinning station Spinning machine fed and refined in the spinning station and then a yarn formation (Rotation or other suitable hardening). That through the Yarn formation is withdrawn from the spinning station.

In the field of spunbonded nonwovens, the Spunbonded tapes or from the spunbonded nonwoven storage or transport units formed, which is then used as the starting product for the actual yarn production become. This measure makes it possible to manufacture the spunbonded nonwoven or the spunbonded nonwoven ribbon (primary spinning mill) and yarn production (secondary Spinning).

The filaments are advantageously stretched and, if necessary, stretched out fixed in such a way that the macromolecules at least partially in the filament direction aligned and held in this orientation. The at least partially drawn filaments can be essentially random or in a predetermined Patterns are filed. For the solidification of the flat filament storage A spunbonded web has various methods known per se. Filaments made of a thermoplastic polymer are made, for example, by pressing between appropriately heated flat pressing agents, i.e. thermally hardened.

There are also solidifications by means of adhesive (chemical solidification) or by means of Pressing or swirling (mechanical strengthening) or mixed forms of Solidifications (e.g. cold bonding or calendering) possible.

The separation of the nonwoven fabric in spunbonded nonwoven tapes is carried out, for example mechanical cutting means performed. By cutting arise on the Long edges of the spunbond tapes of fiber ends (at other points of the There are no such fiber ends in spunbond tapes). When separating the Spunbonded care must be taken to ensure that the fibers are not pulled out of the ribbon and the fiber ends are preferably not welded together. The Length and length distribution of the staple fibers present in the spunbonded nonwoven tapes are directly dependent on the width of the spunbonded ribbon and on the type of Filaments are deposited in the spunbond. The narrower the spunbonded ribbon, the shorter will be the fibers; the more orderly the filament tray, the more uniform it becomes Be stack length. The alignment of the staple fibers in the spunbond nonwoven is also depending on how the filaments are deposited. Since the fiber ends are all at the Long edges of the spunbonded ribbon is a high degree of alignment Longitudinal fibers are not possible. The fineness of the spunbonded ribbon is determined by the spunbond density and the ribbon width.

To refine the spunbond tapes before the yarn is formed, they are envisaged yarn formation, in particular rotation, and depending on Yarn to be produced is drawn in a drafting system or with the help of an opening roller resolved, as is known for conventional staple fiber materials. If necessary, the spunbonded tapes for feeding are for refinement suitable means to compact. With the refinement, the solidification of the Spunbonded structure at least partially dissolved. If this solidification is sufficient is strong or if the pinch point distance is shorter than the majority of the fibers it is also possible to stretch the spunbonded nonwoven to insert the macromolecules into the Parallelize fibers further.

The yarn is formed, for example, by ring spinning, pot spinning, Bell spiders, friction spiders, open-end rotor spiders or air spiders, for what conventional device are applicable. Maximum stretching of the fibers maximum orientation of the macromolecules can also be achieved in the yarn state be characterized in that the yarn, for example, between yarn formation and winding is stretched and thermally fixed.

The solidification of the flat filament deposit is to be chosen in such a way that it Refinement of the spunbonded nonwoven tape can be at least partially dissolved. This is the only way to ensure a real warping of the fiber structure and a high degree of parallelization of the Fibers refined by stretching the spunbond tape and a sufficient one Individualization of the fibers possible when refining by dissolving. In the Strengthening, strong connections between the filaments do indeed require high stretching forces, but allow for refinement by stretching next to one Fiber parallelization also involves fiber stretching or molecular alignment for example, can be thermally fixed in the yarn state.

For the production of blended yarns from various man-made fibers for example, filaments made of different materials are already in the primary spinning process Materials created and essentially stored together are different Spunbonded and brought together or laminated (doubled) or become the secondary Various spunbond tapes are fed to the spinning process at the same time. For the production Mixed yarns made from man-made fibers and natural fibers can also be used Nonwovens (e.g. spunbond and carded nonwovens) are brought together and laminated, which creates a mixed fleece and mixed fleece tapes, or can A natural fiber bandage is added to the spinning process in addition to the spunbonded nonwoven tape become.

Figuren 1 bis 3

drei durch Längsauftrennung eines Spinnvlieses hergestellte Spinnvliesbändchen mit dem zugehörigen Stapeldiagramm (minimale Faserlänge als Funktion des Faseranteils);

Figur 4

die Wirkung der Eigenschaften des Spinnvliesbändchens auf Stapellänge, Stapelverteilung und Vorlagennummer;

Figur 5

eine schematische Darstellung der Schritte des erfindungsgemässen Verfahrens;

Figur 6

eine sehr schematisch dargestellte Einrichtung zur Durchführung des erfindungsgemässen Verfahrens.

The method and device according to the invention are described in detail in connection with the following figures. Show:

Figures 1 to 3

three spunbond tapes produced by longitudinal separation of a spunbonded fabric with the associated stack diagram (minimum fiber length as a function of the fiber content);

Figure 4

the effect of the properties of the spunbonded nonwoven tape on the pile length, pile distribution and template number;

Figure 5

a schematic representation of the steps of the inventive method;

Figure 6

a very schematically illustrated device for performing the inventive method.

FIGS. 1 to 3 show schematic sections of various spunbonded nonwoven tapes which are subjected to a refinement and a yarn formation in the process for yarn production according to the invention. The stack diagrams corresponding to the ribbons are indicated to the right of the ribbon sections. The long edges of the ribbons are illustrated with dash-dotted lines.

The spunbond tapes are made from a spunbond by longitudinal separation, which spunbond consists of a multitude of quasi endless filaments. By the longitudinal separation of the spunbond, the endless filaments are separated, so that staple fibers are formed, the ends of which are all on the longitudinal edges of the ribbons lie. The staple fibers are in the spunbond tapes depending on the strengthening of the Spunbonded fabric advantageously thermally or chemically, or also mechanically connected with each other, the thermal and chemical connection model as fixation of fiber crossings and the mechanical connection as Fiber interlacing can be viewed.

The spunbonded nonwoven tape according to FIG. 1 comes from a spunbonded nonwoven in which the filaments were deposited purely by chance. For this reason, the arrangement of the fibers and thus their length is more or less random. Fibers of very different stack lengths can be expected.

The spunbonded nonwoven tape according to FIG. 2 comes from a spunbonded nonwoven in which the filaments are stored in a strictly ordered manner, for example in two directions obliquely to the longitudinal direction of the nonwoven. Such a spunbonded nonwoven can be produced by cyclically moving the arrangement of spinnerets back and forth, for example during the primary spinning process, transversely to the direction in which the deposited filaments are conveyed away. The speed of the resulting relative movement between the spinnerets and the conveying means must be kept approximately the same as the speed at which the filaments are ejected from the primary spinning device. The stack distribution of a spunbonded nonwoven fabric made from such a spunbonded fabric is rectangular (all fibers are essentially of the same length).

The spunbonded nonwoven tape according to FIG. 3 is made from a spunbonded nonwoven in which the filaments are only roughly arranged. For the production of such a spunbond nonwoven, the spinnerets are in turn moved transversely to the direction of removal of the spunbond, the speed of the movement resulting from the movement of the spinnerets and the removal rate being less than the speed at which the filaments are ejected from the primary spinning device. This results in a fiber length distribution in the spunbonded nonwoven ribbon, which lies between the fiber length distributions of the ribbon according to FIGS. 1 and 2.

It can be clearly seen from FIGS. 1 to 3 that it is possible to use the Fiber length distribution in a manufactured according to the inventive method Yarn on the production of the spunbond, in particular on the way in to control the filaments.

FIG. 4 shows schematically which properties of the spunbonded nonwoven tape have an effect on the fiber material and the yarn produced therefrom, and which properties of the spunbonded nonwoven tape can be influenced on the properties of the fiber material or the yarn produced therefrom.

The stack length and stack distribution is set, as already mentioned above over the filament storage (ordered or tangled) and over the ribbon width. The Original number (mass per unit length in the spunbond tape), which then by Stretching or dissolving to yarn count is essentially due to that Product of the basis weight of the spunbond and the ribbon width given and is set above this basis weight for a given ribbon width.

FIG. 5 schematically shows the steps of the method according to the invention for producing a staple fiber yarn which at least partially consists of man-made fibers.

In a primary spinning step, virtually endless filaments 1 are made from one Plastic material produced (e.g. by extrusion) and advantageously for Increased stretched strength. The stretching can be done with the help of air and in this case only a partial alignment of the macromolecules cause. The stretching can also be effected with the help of godets and one effect substantially full or maximum molecular alignment. In this The filament material then advantageously also becomes a trap Heat set to cause shrinkage when heated later avoid.

Then the filaments 1 are deposited in a flat layer 2. Here is the Conveying speed W less than the filament speed F, so that the deposited filaments, for example, form a random tangle. Like in In connection with Figures 2 and 3 has already been described, it is also possible to deposit the filaments more or less orderly.

In a solidification step that follows the filament deposition step, the Layer 2 of the filaments solidified into a spunbond 3. The solidification is in the figure 5 symbolically by highlighting the places where filaments cross shown. Solidification is for thermoplastic filament materials advantageously a thermal, that is, the filaments are in one plastic state pressed against each other and thereby welded together or glued. When choosing temperature and pressure, it should be borne in mind that the Fiber connection must be at least partially dissolved in the refinement. However, it is also possible to use adhesives (e.g. washable or removable in another suitable way) to introduce the filaments by mechanical or fluid dynamic means swirl or close the filament by calendering or cold bonding solidify.

Before or after the solidification, the filament holder 2 can also do more Staple fiber material are added, for example cotton fibers in the form of a Card web.

In a separation step, the longitudinal separation of the spunbond 3 Spunbond tapes 4 produced as shown in detail in Figures 1 to 3 and are described in connection with these figures. The ends of the Staple fibers that have arisen from the filaments are all on the long edges of the spunbonded ribbon. The fiber arrangement is confused to ordered; the fibers are primarily not arranged parallel to the length of the ribbon. The spunbonded web can rolled up state, for example by means of a grinding cut Circular knives can be separated in spunbonded ribbons or stretched out Condition, for example, by moving over a blade, using scissors, Ripping, water jet cutting, laser cutting etc.

The spunbond webs 4 are then stretched in a refinement step or dissolving (opening) into a spinnable fiber structure 5. there the fiber connections that were created in the consolidation step at least partially torn or loosened and the staple fibers are increased in Running direction aligned.

In a yarn formation step, the spinnable fiber structure is then 5 twists or Rotation granted, resulting in a yarn 6 from the fiber structure 5, the Spools of thread 7 is wound up. Instead of issuing a rotation, another, suitable consolidation (e.g. swirling or gluing) should be provided. If necessary, the yarn 6 between yarn formation and winding complete orientation of the macromolecules in the direction of the fiber still stretched and / or to fix the molecular alignment.

The method according to the invention can be used in the manner described above as a direct one Spinning processes are carried out, from the primary to the secondary Spinning step runs essentially continuously. But since installations for primary and for secondary spinning at least so far with very different ones Delivery speeds work and usually not under the same Management and roof operated, it is advantageous to use the procedure for the Split the area of the primary and secondary spinning step. this will realized by the spunbond 3 rolled up into spunbond rolls 10 or in vessels stored and transported in this form. The first step in the secondary The spinning area is then the separating step in which the spunbond 3 Spunbonded tapes 4 are created. This can be done by unwinding the spunbond 3 and done on-line cutting or by dividing spunbond rolls 10 in Discs, from which the spunbond tapes 4 are then unwound. on the other hand the spunbond nonwoven 3 can also be separated in the primary spinning area become. The spunbond tapes 4 resulting from the separation are then rolled up into ribbon spools 11 or warp-like ribbon rolls 12 and in this Form transported to the area of the secondary spinning step.

Figure 6 shows in a very schematic manner a device for performing the method according to the invention. The figure is divided by a dash-dotted line into an area I of the primary spinning step and an area II of the secondary spinning step.

The area I of the primary spinning step has a means 20 for primary spinning of Filaments 1 made of a plastic material, and a means 21 for storing the Filaments 1 in a flat filament storage 2 and to lead away this flat Filament deposit 2, a means 22 for solidifying the filament deposit 2 into one Spunbond 3 and optionally a means 24 for the production of transport units the spunbond 3 or a means 25 for separating the spunbond 3 in Spunbonded tapes 4 and a means 26 for creating transport units from Spunbonded tapes 4. Between the agent 20 for primary spinning and the agent 21 for storing and conveying away is advantageously a means 20.1 for stretching and Fix or only intended to stretch the filament.

The area II of the secondary spinning step has at least one, advantageously a large number of spinning stations 30, each with a means 31 for refining one Spunbond tape 4, a means 32 for yarn formation and a means 33 for winding of the created yarn 5. The spinning station 30 or the spinning stations A means 34 for removing (unrolling) spunbonded fabric is optionally connected upstream 3 of transport formations combined with a means 25 for separating the Spunbond 3 to spunbond tape 4 or a means 36 to remove (unroll or unwinding) of spunbond tapes 4 from transport units. On the means 32 for Yarn formation is followed, if necessary, by means 32.1 for stretching and fixing or only for fixing the yarn.

The advantages of the method according to the invention over known, Generic methods are that the method according to the invention is about can be designed as simply as direct spinning, but its disadvantages does not have and that it is significantly simpler than the procedure via Staple fiber bale operated.

Claims (24)

Process for the production of staple fiber yarns (6) which at least partially consist of man-made fibers by refining an at least partially made of man-made fiber fibers and then subjecting them to yarn formation, characterized in that the staple fiber association is a spunbonded nonwoven ribbon (4) or a mixed nonwoven ribbon. A method according to claim 1, characterized in that the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon is processed by stretching to a refined fiber structure (5). A method according to claim 1, characterized in that the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon is processed by dissolving into a refined fiber structure (5). Method according to one of claims 1 to 3, characterized in that the refinement is supplied with at least two spunbonded nonwoven tapes (4) or mixed nonwoven tapes made of different materials. Method according to one of claims 1 to 4, characterized in that the refinement in addition to the spunbonded nonwoven ribbon (4) is fed a fiber structure made of natural staple fibers. Method according to one of claims 1 to 5, characterized in that the refined fiber structure (5) is subjected to yarn formation by imparting twist. Method according to claim 6, characterized in that the rotation is ring spinning, pot spinning, bell spinning, friction spinning, open end rotor spinning or air spinning. Method according to one of claims 1 to 5, characterized in that the refined fiber structure (5) is subjected to yarn formation by swirling or gluing. Method according to one of claims 1 to 8, characterized in that the yarn (6) is stretched and fixed or only fixed after the yarn formation. Method according to one of claims 1 to 9, characterized in that the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon is fed to the refinement and yarn formation by a transport unit (11, 12) of such ribbons. Method according to one of claims 1 to 9, characterized in that the spunbonded nonwoven band (4) is fed to the refinement and yarn formation by a transport unit (10) of spunbonded nonwoven (3) or mixed nonwoven, the spunbonded nonwoven (3) or mixed nonwoven being removed during removal the transport unit (10) is cut lengthwise into spunbonded nonwoven tapes (4) or mixed nonwoven tapes. Method according to one of claims 1 to 9, characterized in that the spunbonded nonwoven ribbon (4) is fed directly from a region (I) of a primary spinning process, in which region (I) a spunbonded nonwoven (3) by primary spinning of filaments (1) , is produced by depositing the filaments (1) in a flat filament deposit (2) and by solidifying the flat filament deposit (2) and the spunbonded fabric (3) is cut lengthways into a plurality of spunbonded nonwoven tapes (4). Method according to one of claims 1 to 9, characterized in that the mixed fleece tape (4) is fed directly from a region (I) of a primary spinning process, in which region (I) a mixed fleece (3) by primary spinning of filaments (1) , is produced by depositing the filaments (1) in a flat filament rest (2), by combining with a staple fiber fleece and by strengthening the flat filament rest (2) and the mixed fleece (3) is cut lengthways into a plurality of mixed fleece tapes (4). Method according to claim 12 or 13, characterized in that the filaments (1) are stretched or stretched and fixed before being deposited. Method according to one of claims 1 to 14, characterized in that the chemical fibers are arranged in a random position in the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon. Method according to one of claims 1 to 14, characterized in that the chemical fibers are arranged in the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon or are arranged in a roughly arranged tangle. Method according to one of claims 1 to 16, characterized in that the stack length and the stack length distribution of the man-made fibers in the spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon is adjusted by appropriate choice of the ribbon width and the arrangement of the filaments in the spunbonded nonwoven (3). Method according to one of claims 1 to 17, characterized in that the template number of the spunbonded nonwoven ribbon (4) is set by appropriately selecting the ribbon width and spunbonded nonwoven density. Device for producing staple fiber yarns (6) which at least partially consist of man-made fibers, which device has at least one spinning position (30) for refining a fiber structure and for forming yarn from the refined fiber structure, characterized in that the at least one spinning position (30) has a device for feeding a spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon. Device according to claim 19, characterized in that the device for feeding a spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon has a means (34) for removing a spunbonded nonwoven (3) or mixed nonwoven from a transport unit (10) and a means (25) for longitudinally separating a spunbonded nonwoven (3) or mixed fleece. Device according to claim 19, characterized in that the device for feeding a spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon has a means for removing the ribbon from a transport unit (11, 12). Device according to claim 19, characterized in that the device for feeding a spunbonded nonwoven ribbon (4) or mixed nonwoven ribbon comprises means (20) for primary spinning and stretching of filaments (1), means (21) for depositing the filaments (1) and for The filament tray (2) is carried away, has a means (22) for strengthening the filament tray (2) to form a spunbonded fabric (3) and a means (25) for longitudinally separating the spunbonded fabric (3). Device according to claim 22, characterized in that the device additionally has a means for bringing together the spunbonded nonwoven (3) with a staple fiber nonwoven. Device according to one of claims 20 or 22, characterized in that the means (25) for longitudinally cutting a spunbonded fabric (3) is equipped for the continuous cutting of the spunbonded fabric (3) or for cutting a spunbonded fabric roll (10) into disks.

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