CA1043197A - Spun yarn and process for manufacturing the same - Google Patents
Spun yarn and process for manufacturing the sameInfo
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- CA1043197A CA1043197A CA255,621A CA255621A CA1043197A CA 1043197 A CA1043197 A CA 1043197A CA 255621 A CA255621 A CA 255621A CA 1043197 A CA1043197 A CA 1043197A
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Abstract
ABSTRACT OF THE DISCLOSURE
A spun yard composed of staple fibers has the average number of fibers in cross section, N, and the rate of yarn evenness, CV, such that
A spun yard composed of staple fibers has the average number of fibers in cross section, N, and the rate of yarn evenness, CV, such that
Description
f 1~43~97 This invention relates to a novel spun yarn having a unique configuration and to a process for the manufacture thereof.
. .
More particularly, this invention relates to a novel spun yarn which gives improved efficiency in the manufacture of knitted and woven fabrics and imparts useful properties to the knitted and woven fabrics. The invention also relates to an effective process for the manufacture of such novel spun yarn.
In general, conventional yarns to be used for the manufacture of knitted and woven fabrics are classified into spun yarns and filament yarns.
Although conventional spun yarns have good bulkiness and are accordingly characterized by softness and warmness, they are limited in their uniformity of yarn evenness. More particul-arly, when fine yarn is ma~ufactured from fibers of coarse --~ denier, the yarn evenness becomes remarkably more non-uniform.
; ~hus, knitted and woven fabrics made from conventional spun yarn~ are lacking in surface uniformity and it is especially ~ difficult to manufacture knitted and woven fabrics of high gaug~.
- On the other hand, conventional filament yarns have ~ 20 good uniformity and fine yarns can be manufactured. However, they are lacking in bulkiness and, therefore, knitted and woven ~:` fabrics made from them, although having a uniform surface, are cold and slim-featured. MuCh research effort has been directed ~; towards removing these defects of the conventional yarns, and many methods have been proposed for this purpose.
- Conventional methods for obtaining spun yarns are ;` classified into the card system and the tow system. The tow system includes the perlock system, the tarbo stapler system, the converter system and the direct spinning system. In the card - '' ' `'' .
- i~43~?7 - system, wherein spun yarn is made by opening and rearranging staple fibers from a fiber mass in which the staple fibers are arranged rando~ly, the spun yarn obtained is limited in evenness ; and it is said that the limit of evenness of the spun yarn corresponds to that of random slivers.
. . , In other words, when the average number of fibers in cross sections of spun yarn is N, the rate of yarn evenness of random slivers, CVO, is the following.
:. cvO = loo/J~
And the rate of yarn evenness in the spun yarn obtained by the card system is always beyond the value of the above equation.
The rate of yarn evenness means a coefficient of variation in unevennes~ of fineness of spun yarn, and the lower the value, the better the evenness of yarn. In the tow system, the method of obtaining staple fibers from tow is either to : : .
-- tear off the tow or to cut the tow with a knife.
In the latter case, the end portions of staple fibers obtained are centralized at a specific position along the length ,. . .
of sliver, and therefore a useful yarn cannot be obtained. In order to disperse the cut end portions of staple fibers, doubling and drafting are repeated, so that the uniformity of fineness of - the spun yarn obtained is almost equal to the uniformity in spun yarn obtained by the card system. In the former case, i.e. the method of obtaining sliver by tearing off, the uniformity of thickness of the sliver is deemed to be as follows. The number of filaments, which compose a supplying tow, is represented as n, and it is supposed that all of the filaments are of the same fineness and that the elongation of each filament at tearing off is perfectly recovered. when the tow is torn off at drafting
. .
More particularly, this invention relates to a novel spun yarn which gives improved efficiency in the manufacture of knitted and woven fabrics and imparts useful properties to the knitted and woven fabrics. The invention also relates to an effective process for the manufacture of such novel spun yarn.
In general, conventional yarns to be used for the manufacture of knitted and woven fabrics are classified into spun yarns and filament yarns.
Although conventional spun yarns have good bulkiness and are accordingly characterized by softness and warmness, they are limited in their uniformity of yarn evenness. More particul-arly, when fine yarn is ma~ufactured from fibers of coarse --~ denier, the yarn evenness becomes remarkably more non-uniform.
; ~hus, knitted and woven fabrics made from conventional spun yarn~ are lacking in surface uniformity and it is especially ~ difficult to manufacture knitted and woven fabrics of high gaug~.
- On the other hand, conventional filament yarns have ~ 20 good uniformity and fine yarns can be manufactured. However, they are lacking in bulkiness and, therefore, knitted and woven ~:` fabrics made from them, although having a uniform surface, are cold and slim-featured. MuCh research effort has been directed ~; towards removing these defects of the conventional yarns, and many methods have been proposed for this purpose.
- Conventional methods for obtaining spun yarns are ;` classified into the card system and the tow system. The tow system includes the perlock system, the tarbo stapler system, the converter system and the direct spinning system. In the card - '' ' `'' .
- i~43~?7 - system, wherein spun yarn is made by opening and rearranging staple fibers from a fiber mass in which the staple fibers are arranged rando~ly, the spun yarn obtained is limited in evenness ; and it is said that the limit of evenness of the spun yarn corresponds to that of random slivers.
. . , In other words, when the average number of fibers in cross sections of spun yarn is N, the rate of yarn evenness of random slivers, CVO, is the following.
:. cvO = loo/J~
And the rate of yarn evenness in the spun yarn obtained by the card system is always beyond the value of the above equation.
The rate of yarn evenness means a coefficient of variation in unevennes~ of fineness of spun yarn, and the lower the value, the better the evenness of yarn. In the tow system, the method of obtaining staple fibers from tow is either to : : .
-- tear off the tow or to cut the tow with a knife.
In the latter case, the end portions of staple fibers obtained are centralized at a specific position along the length ,. . .
of sliver, and therefore a useful yarn cannot be obtained. In order to disperse the cut end portions of staple fibers, doubling and drafting are repeated, so that the uniformity of fineness of - the spun yarn obtained is almost equal to the uniformity in spun yarn obtained by the card system. In the former case, i.e. the method of obtaining sliver by tearing off, the uniformity of thickness of the sliver is deemed to be as follows. The number of filaments, which compose a supplying tow, is represented as n, and it is supposed that all of the filaments are of the same fineness and that the elongation of each filament at tearing off is perfectly recovered. when the tow is torn off at drafting
-2-1~3197 f D times to obtain sliver, the average number of fibers in the cross section of the tow becomes n/D. Further, supposing that the cutting of filaments takes place randomly, the proba-bility p of there existing one of the filaments in any given cross section of sliver becomes 1/D and probability q of its non-existing become~ p).
p = l/D
q = 1 - p ~he number of fibers in the cross section of the sliver is obtained by adding them n times, and as a result of binomial distribution, the probabili y P(r) of the number of fibers in the cross section being r becomes the following.
P(r) = nCrprqn~r As the dispersion of data is a binomial distribution is n.p.q and the average value is n.p, the CV% of the data becomes the - following.
~n P q x 100 = ~ x 100 = ~ x 100(/) -n.p ~n.p J n . . .
In other words, when a tow, which is composed of n filament pieces, is torn off at a drafting of D times to obtain ;sliver, supposing that the cutting of filaments takes place randomly, the CV% of the number of fibers in cross section, becomes ~ x 100%.
On the other hand, the CV% of the above mentioned random sliver is 100 %. N is the average number of fibers in cross section, corresponding to n/D in the case of sliver obtained by tearing off the tow, and accordingly the ratio of the CV% of the torn-off sliver to the CV% of the random sliver becomes the following.
.
.
' :- 10~3~97 .' x 100 ~
;~ ¦ D x 100 D
~ ~: J n Generally, in the case of torn-off sliver, the drafting ratio D is much greater than 1 and the value of above equation is almost equal to 1. Therefore, even in the case of torn-off sliver, the uniformity of fineness in the spun yarn obtained is at most the same as the uniformity in the random sliver. As is mentioned above, the conventional ~pinning methods are limited in the uniformity of thickness in the spun yarns obtained.
on the other hand, many methods have been proposed to impart hand feel like spun yarn to filament yarns, as shown in Japanese Patent PublicatiOns Nos. 36-6592, 40-19697 and 49-133639, in which methods of making nap on the surface of filament yarn , ~ ~
: are proposed. However, even though the yarns obtained by these - methods have nap on the surface of yarn and are apparently similar to spun yarn, their bulkiness and softness, and the hand feel of the surface of knitted and woven fabrics made from them are greatly inferior to those of spun yarns.
Another method of manufacturing yarn similar to spun ;. .
yarn from filament yarn has been proposed in Japanese Patent Laying Open No. 50-154550. According to this method, an unoriented polyester yarn is subjected to drafting and heat treat-ment under specific conditions to impart weak points to the filaments and the yarn is torn off to obtain yarn similar to spun yarn.
The end portions of the fibers obtained by this method are not only on the surface of yarn but also inside the yarn and, therefore, the yarn obtained by this method is more similar to spun yarn than those obtained by the above-mentioned conventional methods. However, according to this method, the weak points are -` 1043197 quite randomly distributed in each filament, so that the lengths of the fibers obtained are quite irregular.
Well known methods for manufacturing blended yarns are methods of blending plural staple fibers in a scutching process and methods of blending plural slivers in a drawing process or a gilling process. ~owever, the blended yarns obtained by these methods give rise to problems of non-uniformity of fineness and of low productivity.
Covered yarn is a yarn in which the function of the core component of the yarn is to improve the mechanical pro-perties of the yarn (such as its stretchability, and bending strength) and the function of the covering component is to ;
improve the aesthetic properties of yarn (such as its color, ~ and hand feel). A typical known method for manufacturing covered ,,,- :, - yarn is a method in which a core yarn is fed onto a front roller of a ring spinning frame, and is discharged together with a drafted fleece from the front roller, the yarn thus produced being twisted and taken up.
HoweVer, this method is not efficient because of the ; 20 use of a roving yarn in long spinning processes. Also, in - this method, the fleece which is produced by drafting the roving yarn is limited in its uniformity of thickness, so that an uneven covering tends to appear and lowers the quality of knitted and woven fabrics made from the covered yarn.
It is known that doubling yarn can be directly manufactured by using a pot spinning frame, in which a drafted roving yarn is fed into a cylindrical pot which is rotating at a high speed to twist it, and when the volume of yarn in the pot reaches a predetermined level, the yarn is discharged " ' ' ~"'~ .
together with a separate yarn, and the doubling and twisting yarn thus produced is taken up as a cheese. This method is superior to the methods using a ring spinning frame which require four steps of spinning, rewinding, doubling and twisting.
HOwever, this method has several problems in practice.
A first problem is that it is required to stop the rotation of the pot at the time of yarn breakage. As is well known, when using a pot in the spinning process, the fiber bundle is pressed against the inner wall surface of the pot by :.-; 10 the action of centrifugal force, but when the rotation of the pot is stopped, the fiber bundle inside the pot gets out of shape. Accordingly, when yarn breakage occurs in the pot, the :~ whole yarn therein becomes yarn waste.
A second problem is that it is necessary to rewind the wound yarn in order to remove yarn defects such as slub and-nep.
, This problem is especially troublesome when staple fiber is used ` as a starting material for the spun yarn. Moreover, when removing yarn defects from doubling yarn, the knot portion of the yarn becomes enlarged.
As is mentioned above, the conventional pot spinning methods present various problems and, especially, it is very diPficult to prevent a reduction of efPiciency and yield caused by the occurrence of yarn breakage.
An object of this invention i5 to provide a spun yarn having increased yarn strength without unevenness of yarn.
Another object of this invention is to provide a blended spun yarn composed of at least two kinds of staple fibers, with less unevenness of blend in the radial and longitudinal directions of the spun yarn. Further, another object of this :~ f 10~3197 Invention is to provide a covered yarn with less unevenness of fineness of the covering part of fiber bundle.
Further, another object of this invention is to provide a method for manufacturing the above-mentioned spun yarn directly from continuous multi-filament yarn.
The spun yarn of this invention is composed substan-tially wholly of staple fibers and the average number N of fibers in the cross section and the rate of yarn evenness CV are such that the product CV ~ is within the range of 12.5 ~ CV ~ <100.
In the above inequality the rate of yarn evenness CV is a coefficient of variation in evenness of fineness as shown above, .,, and, in more detail, is a value obtained by multiplying 1.25 by a value showing the average variation value of evenness as a percentage, in which the average variation value of evenness n~ is measured at 25 m/min. by usingi~Yk~ yarn evenness tester in accordance with Japanese Industrial standard JISL 1008, ' cotton yarn testing method 5.18.Z, B,I.
~;. ..
; The staple fibers to be used in this invention are - those obtained by cutting continuous multi-filament yarn, pre-ferably of polyamide or polyester type synthetic fibers. The effective fiber contents of the staple fibers to be used in this invention are preferably more than 25%.
The effective fiber contents are obtained as follows.
Staple fibers are arranged in order of their length, and a so-called staple diagram is prepared. At one end, the longest fiber is arranged and at the other end the shortest is arranged and the distance between thern is divided into 50 equal parts.
49 division points are accordingly obtained and the total fiber length~ at all of the division points are measured.
_7_ . .
' . .
: - ` 1043197 A value obtained by adding the average of the longest fiber length and the shortest fiber length into the above total fiber length is divided by 50 to give the average fibre length ~e .
The effective fiber contents are shown as a percentage of the number of staple fibers within 0.8~ ~ 1.2~e length per the total number of staple fibers. Therefore, the better the uniformity of the length of staple fibers, the higher the effective fiber contents.
he ends of staple fibers in the spun yarns of this , .
invention are present randomly inside and on the surface of yarn.
The staple fibers constituting the spun yarn of this invention may be either non-crimped or coil-like crimped fibers.
. . .
Moreover, the spun yarn of this invention may be composed of at least two kinds of staple fibers, both of which are blended with each other in the cross section of yarn.
In the above blended spun yarn, the average number of - fibers, Nl, N2 ~ and the rate of yarn evenness, CVl, CV2 of each of staple fibers are as follows.
12.5 < CVl < 100 12.5 CV 100 ,__ < 2 <
~ `/N2 ~N2 .
In the above inequalitites, the average number of fibers and the rate of yarn evenness are obtained by counting the number of fibers on 50 cross sections taken at random of the spun yarn by means of microscope.
10~3~97 Moreover, this invention provides a composite yarn which is composed of staple fibers, having the average number of fibers in cross section, N, and the rate of yarn evenness, CV, such that the inequality 12.~ ~ CV ~ ~ 100 is obeyed, and a further yarn. As the further yarn, multi-filament yarn, monofilament yarn, spun yarn, textured yarn, elastic yarn, and the like, can be used.
: ~.
Covered yarn can be manufactured by using the above-mentioned further yarn as the core yarn components. Spun yarn - 10 of this invention can be manufactured as follows.
substantially non-twisted continuous multi-filament yarn fed from a feed roller is contacted with a cutter moving ~, approximately at right angles to the yarn axis so as to cut it into staple-like fibers while maintaining the continuity of the iber bundle, and is discharged by means of delivery roller rotating at the same surface speed as the surface speed of the feed roller, and then the fiber bundle thus obtained is gathered . .
and taken up.
:., The starting material for manufacturing the yarn of ; 20 this invention is continuous multi-filament yarn which is pre-ferably non-twisted and in which each continuous filament is separated from the others.
According to this invention, as the continuous filaments constituting the continuous multi-filament yarn are cut into staples, the continuity of the fiber bundle composed of the staple-like fibers thus produced is maintained. Therefore, it is preferable that the cut points of the continuous filaments are dispersed as randomly as possible. For this reason, the continuous multi-filament yarn is required to be non-twisted, _g _ ,", , 10~3197 and a multi-filament yarn having a twist density of less than 100/m is preferably used.
~ If the twist density is substantially higher than the ; ~ above value or if the continuous filaments are tightly fixed to each other with adhesive, resin or heat welding, only filaments exposed on the surface of the continuous multi-filament yarn are cut, and the filaments existing in the center parts thereof are ; not cut and remain in the continuous state. In such a case, the whole of the continuous multi-filament yarn cannot be cut into uniform staple-like fibers while maintaining continuity of the fiber bundle.
The number of filaments constituting the continuous multi-filament yarn is preferably 15 or more. The more the c~rr~"~
filaments, the better the ~ff~t'~7 of the fiber bundle composed of staple-like fibers which is obtained.
In the above method, the ratio of the surface speed of the delivery roller (or second feed roller) to the surface speed of the feed roller (or first feed roller) is usually . within 1.01 - 1.20. The bending angle of the continuous multi-filament yarn in contact with the cutter is usually within 15 -45. The cutter is preferably composed of a hollow cylindrical rotary device and the continuous multi-filament yarn is cut by contacting it with the inner wall of said cylindrical rotary device.
The speed of the hollow cylindrical rotary device is preferably at least 1,000 rpm. As the supplying yarn, at least two kinds of substantially non-twisted continuous multi-filament yarn can be used, or substantially non-twisted and non-crimped or spiral crimped continuo~ls multi-filament yarn can be used.
,' -10-~, 1043197 - Moreover in the above process, composite yarn can be manufactured by joining the cut fiber bundle together with another yarn fed from the delivery roller. In this case, covered yarn can be manufactured by feeding the other yarn in a state of tension higher than the cut fiber bundle. Also, stretch core yarn can be manufactured by using elastic fibers as the above-mentioned other yarn. According to another embodiment of this invention, substantially non-twisted aontinuous multi-filament yarn is - contacted, through a feed roller, with a cutter moving approxi-mately at right angles to the yarn axis, is cut into staple-like fibers while maintaining the continuity of fiber bundle, and is discharged by means of a delivery roller at a speed approximately equal to the surface speed of the feed roller. The fiber bundle is introduced into a pot rotating at a high speed and is twisted, and then at the time when the yarn content in the pot reaches a predetermined level, the yarn deposited in the pot and the yarn coming continuously into the pot are double discharged from the pot in a twisted condition and are taken up as a doubled and twisted spun yarn.
The invention will now be more fully described, by way of example only, with reference to the accompanying drawings in which:-Figure 1 is a side view schematically illustrating one embodiment of apparatus for practicing the invention;
~ Figure 2 shows the cutter used in the apparatus partly - in section;
Figure 3 schematically illustrates the cutting process;
Figure 4 illustrates an alternative arrangement of cut-; ting devices;
' "' ' ' - -` 10~319~
Figure 5 ~hows a further form of apparatus for carrying :. .
out the invention;
; Figure 6 shows apparatus for producing blended spun yarn;
. - :
. i: ,, Figure 7 shows apparatus for producinq covered spun - yarn: and . .
~ . ~
FigureS8 and 9 show the operation of apparatus for producing doubled yarn.
,.~
In the apparatus of FigUre 1, continuous multi-filament yarn 2 taken up from a package 1 is supplied through a first feed rollers 3 into a cutter 4 which is provided between the feed rollers 3 and de~very rollers 5, the cut staple-like fiber bundle 2a being discharged by the delivery rollers 5. Then, the cut staple-like fiber bundle 2b is supplied into a twisting machine 9, which is e~uipped with a ring 6, a spindle 7 and a traveler 8, and lS taken up on a pirn 10.
As the cutter to be used in this invention, a hollow cylindrical rotary device as shown in FigUre 2 is preferably used. This compriseq a hollow cylindrical rotary device 4a connected with a hollow spindle 4c through a supporting device 4b.
The continuous multi-filament yarn is contacted with ~- the inner surface of the hollow cylindrical rotary device 4a.
; The portion of the cutter in contact with the continuous multi-filament yarn has an abrasive surface composed of, for instance, sand or like abrasive particles having sharp edges.
The ratio of the surface speed of the second delivery rollers 5 to that of the first feed rollers 3 is of importance in order to cut the continuous filaments of continuous multi-filament yarn into good staple-like fibers, and preferably is .
,i . , ~
` 1043~ 9~
Within the range 1.01 - 1.20. If the ratio is less than 1.01, an adequate cutting of the filaments cannot be attained. -If the ratio is greater than 1.20, it is difficult to maintain the continuity of the fiber bundle composed of staple-like fibers which is produced by cutting the continuous filaments .~: .
~ of the continuous multi-filament yarn, and accordingly it .'.
becomes difficult to manufacture the spun yarn continuously.
If a ratio of less than 1.01, for instance, 1 must be used, the multi~filament yarn must be given a pretension before said yarn reaches the feed rollers of the same magnitude as the tension which would be given to the multi-filament between the feed rollers and delivery rollers in the procedure described ; above. -~
The speed of rotation of the hollow cylindrical rotary device 4a and the bending angle of the continuous multi-filament ; yarn presented in contact with the inner surface of hollow cylindrical rotary device are related to the cutting efficiency.
The rotation speed of the hollow cylindrical rotary -device is preferably at least 1,000 rpm. If the rotation speed -is less than 1,000 rpm., the cutting of the filaments is insuf-~; ficient. The bending angle is preferably within 15 - 45. If the angle is less than 15, an adequate cutting of the filaments cannot be attained. If the angle is more than 45, the cutting point is centralized, and accordingly it is difficult to manufac-ture the spun yarn continuously and the strength of obtained spun yarn is lowered remarkably. According to this invention, substantially non-twisted continuous multi-filament yarn is cut by means of the hollow cylindrical rotary device and rollers into staple-like fibers and the product is discharged in the . .
:: 1043197 form of a continuous fleece-like staple fiber bundle.
Figure 3 briefly shows this cutting process. In Figure 3, the step in which one of the continuous filaments is cut is shown, and the thread line between the feed rollers 3 and the delivery rollers 5 is shown as a straight line for the sake of brevity of explanation.
At (a) is shown a state just prior to the cutting of the continuous filament 2 by means of the cutter 4 (hollow cylindrical rotary device). The reference letter A shows the position of the end of the filament produced in the preceding cutting. Supposing that the cutting position is C at which the filament is contacted with the cutter 4, then the cut fiber length is equal to the distance AC.
At (b) is shown the fiber's passage after cutting, the cut fiber on the delivery roller 5 side being transfered to the left by said roller at the same speed as said roller, and the fiber on the feed roller 3 side being also transfered to the left at the same speed as said roller 3. In this case, the end of the cut fiber is supported in straight form by friction with surrounding fibers.
At (c) is shown the state at the time when the end of the fiber on the feed roller 3 side reaches the nip F of the delivery roller 5. The continuous multi-filament yarn 2 is nipped by both the first feed roller 3 and the delivery roller 5, and begins to be elongated between the two nip points F and B
and thus reaches the state shown at (a) again. The cut fiber length is equal to the distance between the two rollers AC which is equal to the sum of the distance FC between the cutter 4 and the nip of delivery rollers and the distance AF. The distance . , AF is equal to the length of continuous multi-filament yarn 2 `, transferred by the delivery rollers 5 between the nip of the delivery rollers 5 and the cutting point. ThiS length AF depend~
on the ratio R of the surface speecls of the two sets of rollers, the distance L2 between the two sets of rollers, and the elon-gation ~ of th~ fiber at cutting.
AF = L2 loge (R-l) (1+) R-(l+~) The cut fiber length L is as follows, wherein the distance FC between the cutter 4 and the nip of the delivery - 10 rollers 5 is shown as Ll.
- L = Ll + L2 loge ( R-(l+~
The above equation was obtained from consideration of ; the draft-cutting fiber length in tow spinning and the like but --~; is also applicable to this invention. However, there is some difference between the two methods. That is, in the case of the ... .
draft-cutting by the known method, the cutting positions of the fibers are not constant and Ll in the above equation accordingly .;
changes widely. Further, the draft corresponding to R in the above equation is much greater and the elongation of the fiber at cutting is also greater than that ~f this invention. Therefore, the yarn obtained by the known method has unevenness in the cut fiber length, unevenness of fineness of the fiber bundle and an excessive shrinking percentage. ~he cutting device can also be arranged, shown in Figure 4, so as to treat plural multi-filament yarns 2, in which plural cutting devices 4 are arranged between .
plural feed rollers 3 and plural delivery rollers 5.
In Figure S, a feed roller 3a is used in place of the first and second feed rollers, and the multi-filament yarn 2 is - supplied, through the feed roller 3a, to a guide roller 11, and ; -15-. . ~.
~ ` 1043197 is cut by the cutter 4 prior to returning to the feed roller 3a and then is discharged as staple fiber bundle. As the means for joining the fibers in the form of yarn, a twisting method using a ring traveler system, a twisting method using an open-end spinning system, a self-twisting method or an adhesive method combining false twisting and heat adhesion can be used. As the non-twisted continuous multi-filament yarn to be used in this invention, crimped yarn such as false twisted yarn can be used.
This crimping process can be incorporated into the process for manufacturing spun yarn of this invention.
The process for manufacturing the spun yarn of this invention can be incorporated into the process for manufacturing the continuous multi-filament yarn used as the starting material.
Also, as the continuous multi-filament yarn, yarn com-posed of dirferent components can be used, the components differ-ing, for example, by being different kinds of fibers, different filaments, or having different crimped forms or different shrinking percentages.
As is shown in Figure 4, using plural cutters arranged in a row, cut fiber bundles each of which have different fiber length can be joined to produce a blended spun yarn.
Figure 6 shows one embodiment of apparatus for manu-facturing a blended spun yarn in this invention.
Different kinds of continuous multi-filament yarns 2, 2' taken up from the package 1, 1' are guided and supplied through feed rollers 3 into the hollow cylindrical device 4a which is provided between the first or feed rollers 3 and the --delivery rollers 5 to be cut into staple-like fibers, and are blended through the positions of the bundles being changed . ~
~ ~0~3197 relative to one another. The blended fiber ~undle 2a is discharged by the delivery rollers 5. Then, the fiber bundle 2a thus produced is supplied into a twisting device 9 which is equipped with a ring 6, a spindle 7 and a traveler 8 to be twisted and taken up on a ~;`- pirn 10.
. . .
Figure 7 shows one embodiment of apparatus for manufac-turing a covered spun yarn in this invention.
Continuous multi-filament yarn 2, which is the starting material for the covering part, is supplied through the first or feed rollers 3 into the hollow cylindrical device 4 and delivered through the delivery rollers 5~
The other yarn 12, which is the starting mRterial for : .
the core part, is supplied by a third feed roller 13 from a ~; package 14 and is joined with the fiber bundle 2a at the second or delivery rollers 5.
;~ The united bundle is delivered from the second rollers 5, and is twisted by the spindle 7 and the ring traveler 9, and is taken up on the pirn 10 as oovered yarn. In this case, the said ..... .
other yarn 12 is preferably supplied in a state of ten3ion higher - 20 than the fiber bundle 2a. As the said other yarn, an elastic yarn - such as polyurethane yarn can be used.
Covered yarn having high stretchability can be obtained Y by supplying the elastic yarn in a tensioned state to the delivery rollers 5.
: Figures 8 and 9 show one embodiment of apparatus for manufacturing doubled yarn in this invention.
The continuous multi-filament yarn 2 is supplied from the package 1 through the feed rollers 3 into the cutter 4 whieh is provided between the feed rollers 3 and the delivery rollers 5. The , ,' .
.
f -~
- ` c~t staple-like fiber bundle 2a is delivered by the delivery rollers 5 and is introduced through a yarn guide pipe 16 into a pot 17 rotating at a high speed.
The yarn guide 16 is in reciprocatirlg motion so as to make a uniform yarn layer 18 in the pot 17.
The yarn 19 guided into the pot 17 is pressed against the inner surface by centrifugal force to ~orm the yarn layer 18 and is twisted as a result of the rotation of the pot 17. In the drawing, 20 indicates take-up rollers, 21 is a taking-up drum and 22 is a taking up bobbin.
In the above mentioned operation, the yarn layer 18 increases with time, and when the yarn layer reaches a predetermined level or after a predetermined time from the starting of yarn storage in the pot 17, the yarn pas~ing through the yarn guiae pipe 16 is discharged downwards together with yarn from the yarn layer through a yarn discharge pipe 23 and is taken up through the take up rollers 20 onto the bobbin 22 by means of the taking-up . . .
drum 21, as shown in Figure 9.
The direction of travel of the yarn discharged from the yarn layer 18 stored in the pot 17 is reversed as compared with its former direction, and accordingly the yarn becomes reversely twisted as it is discharged together with the yarn 1~ supplied by the yarn guide pipe 16 through the yarn discharge pipe 23. A
doubled yarn is thus obtained, and when the yarn layer 18 in the pot 17 is exhausted, discharging of the doubled yarn from the yarn discharge pipe 23 is stopped and storage of yarn into the pot 17 is started again.
By repeating the above-mentioned steps, doubled yarn 24 made of spun yarn is manufactured directly from the continuous ":
. ~ , . , ~ ':
- , . ' ', multi-filament yarn 2. 1043~97 The advantages of this invention can be summarized as follows.
(1) The spun yarn of this invention has excellent uniformity of thickness as shown by the average number of fibers in ; cross section, N, and the rate of yarn evenness, CV being ;:;
such that the inequality 12.5 < CV~N ~ 100 is obeyed, and accordingly knitted and woven fabrics manufactured therefrom have excellent uniformity of surface, and the manufacture of knitted and woven fabrics can be conducted quite efficiently. Further, knitted and woven fabrics can be manufactured having high gauge which can not be attained using the conventional spun yarns.
~- (2) The spun yarn of this invention is composed of staple , . ' :' ; fibers with effective fiber contents of more than 25%, and accordingly it has satisfactory strength, and there is less scattering of short fibers during knitting ~ processe~ or the like.
p = l/D
q = 1 - p ~he number of fibers in the cross section of the sliver is obtained by adding them n times, and as a result of binomial distribution, the probabili y P(r) of the number of fibers in the cross section being r becomes the following.
P(r) = nCrprqn~r As the dispersion of data is a binomial distribution is n.p.q and the average value is n.p, the CV% of the data becomes the - following.
~n P q x 100 = ~ x 100 = ~ x 100(/) -n.p ~n.p J n . . .
In other words, when a tow, which is composed of n filament pieces, is torn off at a drafting of D times to obtain ;sliver, supposing that the cutting of filaments takes place randomly, the CV% of the number of fibers in cross section, becomes ~ x 100%.
On the other hand, the CV% of the above mentioned random sliver is 100 %. N is the average number of fibers in cross section, corresponding to n/D in the case of sliver obtained by tearing off the tow, and accordingly the ratio of the CV% of the torn-off sliver to the CV% of the random sliver becomes the following.
.
.
' :- 10~3~97 .' x 100 ~
;~ ¦ D x 100 D
~ ~: J n Generally, in the case of torn-off sliver, the drafting ratio D is much greater than 1 and the value of above equation is almost equal to 1. Therefore, even in the case of torn-off sliver, the uniformity of fineness in the spun yarn obtained is at most the same as the uniformity in the random sliver. As is mentioned above, the conventional ~pinning methods are limited in the uniformity of thickness in the spun yarns obtained.
on the other hand, many methods have been proposed to impart hand feel like spun yarn to filament yarns, as shown in Japanese Patent PublicatiOns Nos. 36-6592, 40-19697 and 49-133639, in which methods of making nap on the surface of filament yarn , ~ ~
: are proposed. However, even though the yarns obtained by these - methods have nap on the surface of yarn and are apparently similar to spun yarn, their bulkiness and softness, and the hand feel of the surface of knitted and woven fabrics made from them are greatly inferior to those of spun yarns.
Another method of manufacturing yarn similar to spun ;. .
yarn from filament yarn has been proposed in Japanese Patent Laying Open No. 50-154550. According to this method, an unoriented polyester yarn is subjected to drafting and heat treat-ment under specific conditions to impart weak points to the filaments and the yarn is torn off to obtain yarn similar to spun yarn.
The end portions of the fibers obtained by this method are not only on the surface of yarn but also inside the yarn and, therefore, the yarn obtained by this method is more similar to spun yarn than those obtained by the above-mentioned conventional methods. However, according to this method, the weak points are -` 1043197 quite randomly distributed in each filament, so that the lengths of the fibers obtained are quite irregular.
Well known methods for manufacturing blended yarns are methods of blending plural staple fibers in a scutching process and methods of blending plural slivers in a drawing process or a gilling process. ~owever, the blended yarns obtained by these methods give rise to problems of non-uniformity of fineness and of low productivity.
Covered yarn is a yarn in which the function of the core component of the yarn is to improve the mechanical pro-perties of the yarn (such as its stretchability, and bending strength) and the function of the covering component is to ;
improve the aesthetic properties of yarn (such as its color, ~ and hand feel). A typical known method for manufacturing covered ,,,- :, - yarn is a method in which a core yarn is fed onto a front roller of a ring spinning frame, and is discharged together with a drafted fleece from the front roller, the yarn thus produced being twisted and taken up.
HoweVer, this method is not efficient because of the ; 20 use of a roving yarn in long spinning processes. Also, in - this method, the fleece which is produced by drafting the roving yarn is limited in its uniformity of thickness, so that an uneven covering tends to appear and lowers the quality of knitted and woven fabrics made from the covered yarn.
It is known that doubling yarn can be directly manufactured by using a pot spinning frame, in which a drafted roving yarn is fed into a cylindrical pot which is rotating at a high speed to twist it, and when the volume of yarn in the pot reaches a predetermined level, the yarn is discharged " ' ' ~"'~ .
together with a separate yarn, and the doubling and twisting yarn thus produced is taken up as a cheese. This method is superior to the methods using a ring spinning frame which require four steps of spinning, rewinding, doubling and twisting.
HOwever, this method has several problems in practice.
A first problem is that it is required to stop the rotation of the pot at the time of yarn breakage. As is well known, when using a pot in the spinning process, the fiber bundle is pressed against the inner wall surface of the pot by :.-; 10 the action of centrifugal force, but when the rotation of the pot is stopped, the fiber bundle inside the pot gets out of shape. Accordingly, when yarn breakage occurs in the pot, the :~ whole yarn therein becomes yarn waste.
A second problem is that it is necessary to rewind the wound yarn in order to remove yarn defects such as slub and-nep.
, This problem is especially troublesome when staple fiber is used ` as a starting material for the spun yarn. Moreover, when removing yarn defects from doubling yarn, the knot portion of the yarn becomes enlarged.
As is mentioned above, the conventional pot spinning methods present various problems and, especially, it is very diPficult to prevent a reduction of efPiciency and yield caused by the occurrence of yarn breakage.
An object of this invention i5 to provide a spun yarn having increased yarn strength without unevenness of yarn.
Another object of this invention is to provide a blended spun yarn composed of at least two kinds of staple fibers, with less unevenness of blend in the radial and longitudinal directions of the spun yarn. Further, another object of this :~ f 10~3197 Invention is to provide a covered yarn with less unevenness of fineness of the covering part of fiber bundle.
Further, another object of this invention is to provide a method for manufacturing the above-mentioned spun yarn directly from continuous multi-filament yarn.
The spun yarn of this invention is composed substan-tially wholly of staple fibers and the average number N of fibers in the cross section and the rate of yarn evenness CV are such that the product CV ~ is within the range of 12.5 ~ CV ~ <100.
In the above inequality the rate of yarn evenness CV is a coefficient of variation in evenness of fineness as shown above, .,, and, in more detail, is a value obtained by multiplying 1.25 by a value showing the average variation value of evenness as a percentage, in which the average variation value of evenness n~ is measured at 25 m/min. by usingi~Yk~ yarn evenness tester in accordance with Japanese Industrial standard JISL 1008, ' cotton yarn testing method 5.18.Z, B,I.
~;. ..
; The staple fibers to be used in this invention are - those obtained by cutting continuous multi-filament yarn, pre-ferably of polyamide or polyester type synthetic fibers. The effective fiber contents of the staple fibers to be used in this invention are preferably more than 25%.
The effective fiber contents are obtained as follows.
Staple fibers are arranged in order of their length, and a so-called staple diagram is prepared. At one end, the longest fiber is arranged and at the other end the shortest is arranged and the distance between thern is divided into 50 equal parts.
49 division points are accordingly obtained and the total fiber length~ at all of the division points are measured.
_7_ . .
' . .
: - ` 1043197 A value obtained by adding the average of the longest fiber length and the shortest fiber length into the above total fiber length is divided by 50 to give the average fibre length ~e .
The effective fiber contents are shown as a percentage of the number of staple fibers within 0.8~ ~ 1.2~e length per the total number of staple fibers. Therefore, the better the uniformity of the length of staple fibers, the higher the effective fiber contents.
he ends of staple fibers in the spun yarns of this , .
invention are present randomly inside and on the surface of yarn.
The staple fibers constituting the spun yarn of this invention may be either non-crimped or coil-like crimped fibers.
. . .
Moreover, the spun yarn of this invention may be composed of at least two kinds of staple fibers, both of which are blended with each other in the cross section of yarn.
In the above blended spun yarn, the average number of - fibers, Nl, N2 ~ and the rate of yarn evenness, CVl, CV2 of each of staple fibers are as follows.
12.5 < CVl < 100 12.5 CV 100 ,__ < 2 <
~ `/N2 ~N2 .
In the above inequalitites, the average number of fibers and the rate of yarn evenness are obtained by counting the number of fibers on 50 cross sections taken at random of the spun yarn by means of microscope.
10~3~97 Moreover, this invention provides a composite yarn which is composed of staple fibers, having the average number of fibers in cross section, N, and the rate of yarn evenness, CV, such that the inequality 12.~ ~ CV ~ ~ 100 is obeyed, and a further yarn. As the further yarn, multi-filament yarn, monofilament yarn, spun yarn, textured yarn, elastic yarn, and the like, can be used.
: ~.
Covered yarn can be manufactured by using the above-mentioned further yarn as the core yarn components. Spun yarn - 10 of this invention can be manufactured as follows.
substantially non-twisted continuous multi-filament yarn fed from a feed roller is contacted with a cutter moving ~, approximately at right angles to the yarn axis so as to cut it into staple-like fibers while maintaining the continuity of the iber bundle, and is discharged by means of delivery roller rotating at the same surface speed as the surface speed of the feed roller, and then the fiber bundle thus obtained is gathered . .
and taken up.
:., The starting material for manufacturing the yarn of ; 20 this invention is continuous multi-filament yarn which is pre-ferably non-twisted and in which each continuous filament is separated from the others.
According to this invention, as the continuous filaments constituting the continuous multi-filament yarn are cut into staples, the continuity of the fiber bundle composed of the staple-like fibers thus produced is maintained. Therefore, it is preferable that the cut points of the continuous filaments are dispersed as randomly as possible. For this reason, the continuous multi-filament yarn is required to be non-twisted, _g _ ,", , 10~3197 and a multi-filament yarn having a twist density of less than 100/m is preferably used.
~ If the twist density is substantially higher than the ; ~ above value or if the continuous filaments are tightly fixed to each other with adhesive, resin or heat welding, only filaments exposed on the surface of the continuous multi-filament yarn are cut, and the filaments existing in the center parts thereof are ; not cut and remain in the continuous state. In such a case, the whole of the continuous multi-filament yarn cannot be cut into uniform staple-like fibers while maintaining continuity of the fiber bundle.
The number of filaments constituting the continuous multi-filament yarn is preferably 15 or more. The more the c~rr~"~
filaments, the better the ~ff~t'~7 of the fiber bundle composed of staple-like fibers which is obtained.
In the above method, the ratio of the surface speed of the delivery roller (or second feed roller) to the surface speed of the feed roller (or first feed roller) is usually . within 1.01 - 1.20. The bending angle of the continuous multi-filament yarn in contact with the cutter is usually within 15 -45. The cutter is preferably composed of a hollow cylindrical rotary device and the continuous multi-filament yarn is cut by contacting it with the inner wall of said cylindrical rotary device.
The speed of the hollow cylindrical rotary device is preferably at least 1,000 rpm. As the supplying yarn, at least two kinds of substantially non-twisted continuous multi-filament yarn can be used, or substantially non-twisted and non-crimped or spiral crimped continuo~ls multi-filament yarn can be used.
,' -10-~, 1043197 - Moreover in the above process, composite yarn can be manufactured by joining the cut fiber bundle together with another yarn fed from the delivery roller. In this case, covered yarn can be manufactured by feeding the other yarn in a state of tension higher than the cut fiber bundle. Also, stretch core yarn can be manufactured by using elastic fibers as the above-mentioned other yarn. According to another embodiment of this invention, substantially non-twisted aontinuous multi-filament yarn is - contacted, through a feed roller, with a cutter moving approxi-mately at right angles to the yarn axis, is cut into staple-like fibers while maintaining the continuity of fiber bundle, and is discharged by means of a delivery roller at a speed approximately equal to the surface speed of the feed roller. The fiber bundle is introduced into a pot rotating at a high speed and is twisted, and then at the time when the yarn content in the pot reaches a predetermined level, the yarn deposited in the pot and the yarn coming continuously into the pot are double discharged from the pot in a twisted condition and are taken up as a doubled and twisted spun yarn.
The invention will now be more fully described, by way of example only, with reference to the accompanying drawings in which:-Figure 1 is a side view schematically illustrating one embodiment of apparatus for practicing the invention;
~ Figure 2 shows the cutter used in the apparatus partly - in section;
Figure 3 schematically illustrates the cutting process;
Figure 4 illustrates an alternative arrangement of cut-; ting devices;
' "' ' ' - -` 10~319~
Figure 5 ~hows a further form of apparatus for carrying :. .
out the invention;
; Figure 6 shows apparatus for producing blended spun yarn;
. - :
. i: ,, Figure 7 shows apparatus for producinq covered spun - yarn: and . .
~ . ~
FigureS8 and 9 show the operation of apparatus for producing doubled yarn.
,.~
In the apparatus of FigUre 1, continuous multi-filament yarn 2 taken up from a package 1 is supplied through a first feed rollers 3 into a cutter 4 which is provided between the feed rollers 3 and de~very rollers 5, the cut staple-like fiber bundle 2a being discharged by the delivery rollers 5. Then, the cut staple-like fiber bundle 2b is supplied into a twisting machine 9, which is e~uipped with a ring 6, a spindle 7 and a traveler 8, and lS taken up on a pirn 10.
As the cutter to be used in this invention, a hollow cylindrical rotary device as shown in FigUre 2 is preferably used. This compriseq a hollow cylindrical rotary device 4a connected with a hollow spindle 4c through a supporting device 4b.
The continuous multi-filament yarn is contacted with ~- the inner surface of the hollow cylindrical rotary device 4a.
; The portion of the cutter in contact with the continuous multi-filament yarn has an abrasive surface composed of, for instance, sand or like abrasive particles having sharp edges.
The ratio of the surface speed of the second delivery rollers 5 to that of the first feed rollers 3 is of importance in order to cut the continuous filaments of continuous multi-filament yarn into good staple-like fibers, and preferably is .
,i . , ~
` 1043~ 9~
Within the range 1.01 - 1.20. If the ratio is less than 1.01, an adequate cutting of the filaments cannot be attained. -If the ratio is greater than 1.20, it is difficult to maintain the continuity of the fiber bundle composed of staple-like fibers which is produced by cutting the continuous filaments .~: .
~ of the continuous multi-filament yarn, and accordingly it .'.
becomes difficult to manufacture the spun yarn continuously.
If a ratio of less than 1.01, for instance, 1 must be used, the multi~filament yarn must be given a pretension before said yarn reaches the feed rollers of the same magnitude as the tension which would be given to the multi-filament between the feed rollers and delivery rollers in the procedure described ; above. -~
The speed of rotation of the hollow cylindrical rotary device 4a and the bending angle of the continuous multi-filament ; yarn presented in contact with the inner surface of hollow cylindrical rotary device are related to the cutting efficiency.
The rotation speed of the hollow cylindrical rotary -device is preferably at least 1,000 rpm. If the rotation speed -is less than 1,000 rpm., the cutting of the filaments is insuf-~; ficient. The bending angle is preferably within 15 - 45. If the angle is less than 15, an adequate cutting of the filaments cannot be attained. If the angle is more than 45, the cutting point is centralized, and accordingly it is difficult to manufac-ture the spun yarn continuously and the strength of obtained spun yarn is lowered remarkably. According to this invention, substantially non-twisted continuous multi-filament yarn is cut by means of the hollow cylindrical rotary device and rollers into staple-like fibers and the product is discharged in the . .
:: 1043197 form of a continuous fleece-like staple fiber bundle.
Figure 3 briefly shows this cutting process. In Figure 3, the step in which one of the continuous filaments is cut is shown, and the thread line between the feed rollers 3 and the delivery rollers 5 is shown as a straight line for the sake of brevity of explanation.
At (a) is shown a state just prior to the cutting of the continuous filament 2 by means of the cutter 4 (hollow cylindrical rotary device). The reference letter A shows the position of the end of the filament produced in the preceding cutting. Supposing that the cutting position is C at which the filament is contacted with the cutter 4, then the cut fiber length is equal to the distance AC.
At (b) is shown the fiber's passage after cutting, the cut fiber on the delivery roller 5 side being transfered to the left by said roller at the same speed as said roller, and the fiber on the feed roller 3 side being also transfered to the left at the same speed as said roller 3. In this case, the end of the cut fiber is supported in straight form by friction with surrounding fibers.
At (c) is shown the state at the time when the end of the fiber on the feed roller 3 side reaches the nip F of the delivery roller 5. The continuous multi-filament yarn 2 is nipped by both the first feed roller 3 and the delivery roller 5, and begins to be elongated between the two nip points F and B
and thus reaches the state shown at (a) again. The cut fiber length is equal to the distance between the two rollers AC which is equal to the sum of the distance FC between the cutter 4 and the nip of delivery rollers and the distance AF. The distance . , AF is equal to the length of continuous multi-filament yarn 2 `, transferred by the delivery rollers 5 between the nip of the delivery rollers 5 and the cutting point. ThiS length AF depend~
on the ratio R of the surface speecls of the two sets of rollers, the distance L2 between the two sets of rollers, and the elon-gation ~ of th~ fiber at cutting.
AF = L2 loge (R-l) (1+) R-(l+~) The cut fiber length L is as follows, wherein the distance FC between the cutter 4 and the nip of the delivery - 10 rollers 5 is shown as Ll.
- L = Ll + L2 loge ( R-(l+~
The above equation was obtained from consideration of ; the draft-cutting fiber length in tow spinning and the like but --~; is also applicable to this invention. However, there is some difference between the two methods. That is, in the case of the ... .
draft-cutting by the known method, the cutting positions of the fibers are not constant and Ll in the above equation accordingly .;
changes widely. Further, the draft corresponding to R in the above equation is much greater and the elongation of the fiber at cutting is also greater than that ~f this invention. Therefore, the yarn obtained by the known method has unevenness in the cut fiber length, unevenness of fineness of the fiber bundle and an excessive shrinking percentage. ~he cutting device can also be arranged, shown in Figure 4, so as to treat plural multi-filament yarns 2, in which plural cutting devices 4 are arranged between .
plural feed rollers 3 and plural delivery rollers 5.
In Figure S, a feed roller 3a is used in place of the first and second feed rollers, and the multi-filament yarn 2 is - supplied, through the feed roller 3a, to a guide roller 11, and ; -15-. . ~.
~ ` 1043197 is cut by the cutter 4 prior to returning to the feed roller 3a and then is discharged as staple fiber bundle. As the means for joining the fibers in the form of yarn, a twisting method using a ring traveler system, a twisting method using an open-end spinning system, a self-twisting method or an adhesive method combining false twisting and heat adhesion can be used. As the non-twisted continuous multi-filament yarn to be used in this invention, crimped yarn such as false twisted yarn can be used.
This crimping process can be incorporated into the process for manufacturing spun yarn of this invention.
The process for manufacturing the spun yarn of this invention can be incorporated into the process for manufacturing the continuous multi-filament yarn used as the starting material.
Also, as the continuous multi-filament yarn, yarn com-posed of dirferent components can be used, the components differ-ing, for example, by being different kinds of fibers, different filaments, or having different crimped forms or different shrinking percentages.
As is shown in Figure 4, using plural cutters arranged in a row, cut fiber bundles each of which have different fiber length can be joined to produce a blended spun yarn.
Figure 6 shows one embodiment of apparatus for manu-facturing a blended spun yarn in this invention.
Different kinds of continuous multi-filament yarns 2, 2' taken up from the package 1, 1' are guided and supplied through feed rollers 3 into the hollow cylindrical device 4a which is provided between the first or feed rollers 3 and the --delivery rollers 5 to be cut into staple-like fibers, and are blended through the positions of the bundles being changed . ~
~ ~0~3197 relative to one another. The blended fiber ~undle 2a is discharged by the delivery rollers 5. Then, the fiber bundle 2a thus produced is supplied into a twisting device 9 which is equipped with a ring 6, a spindle 7 and a traveler 8 to be twisted and taken up on a ~;`- pirn 10.
. . .
Figure 7 shows one embodiment of apparatus for manufac-turing a covered spun yarn in this invention.
Continuous multi-filament yarn 2, which is the starting material for the covering part, is supplied through the first or feed rollers 3 into the hollow cylindrical device 4 and delivered through the delivery rollers 5~
The other yarn 12, which is the starting mRterial for : .
the core part, is supplied by a third feed roller 13 from a ~; package 14 and is joined with the fiber bundle 2a at the second or delivery rollers 5.
;~ The united bundle is delivered from the second rollers 5, and is twisted by the spindle 7 and the ring traveler 9, and is taken up on the pirn 10 as oovered yarn. In this case, the said ..... .
other yarn 12 is preferably supplied in a state of ten3ion higher - 20 than the fiber bundle 2a. As the said other yarn, an elastic yarn - such as polyurethane yarn can be used.
Covered yarn having high stretchability can be obtained Y by supplying the elastic yarn in a tensioned state to the delivery rollers 5.
: Figures 8 and 9 show one embodiment of apparatus for manufacturing doubled yarn in this invention.
The continuous multi-filament yarn 2 is supplied from the package 1 through the feed rollers 3 into the cutter 4 whieh is provided between the feed rollers 3 and the delivery rollers 5. The , ,' .
.
f -~
- ` c~t staple-like fiber bundle 2a is delivered by the delivery rollers 5 and is introduced through a yarn guide pipe 16 into a pot 17 rotating at a high speed.
The yarn guide 16 is in reciprocatirlg motion so as to make a uniform yarn layer 18 in the pot 17.
The yarn 19 guided into the pot 17 is pressed against the inner surface by centrifugal force to ~orm the yarn layer 18 and is twisted as a result of the rotation of the pot 17. In the drawing, 20 indicates take-up rollers, 21 is a taking-up drum and 22 is a taking up bobbin.
In the above mentioned operation, the yarn layer 18 increases with time, and when the yarn layer reaches a predetermined level or after a predetermined time from the starting of yarn storage in the pot 17, the yarn pas~ing through the yarn guiae pipe 16 is discharged downwards together with yarn from the yarn layer through a yarn discharge pipe 23 and is taken up through the take up rollers 20 onto the bobbin 22 by means of the taking-up . . .
drum 21, as shown in Figure 9.
The direction of travel of the yarn discharged from the yarn layer 18 stored in the pot 17 is reversed as compared with its former direction, and accordingly the yarn becomes reversely twisted as it is discharged together with the yarn 1~ supplied by the yarn guide pipe 16 through the yarn discharge pipe 23. A
doubled yarn is thus obtained, and when the yarn layer 18 in the pot 17 is exhausted, discharging of the doubled yarn from the yarn discharge pipe 23 is stopped and storage of yarn into the pot 17 is started again.
By repeating the above-mentioned steps, doubled yarn 24 made of spun yarn is manufactured directly from the continuous ":
. ~ , . , ~ ':
- , . ' ', multi-filament yarn 2. 1043~97 The advantages of this invention can be summarized as follows.
(1) The spun yarn of this invention has excellent uniformity of thickness as shown by the average number of fibers in ; cross section, N, and the rate of yarn evenness, CV being ;:;
such that the inequality 12.5 < CV~N ~ 100 is obeyed, and accordingly knitted and woven fabrics manufactured therefrom have excellent uniformity of surface, and the manufacture of knitted and woven fabrics can be conducted quite efficiently. Further, knitted and woven fabrics can be manufactured having high gauge which can not be attained using the conventional spun yarns.
~- (2) The spun yarn of this invention is composed of staple , . ' :' ; fibers with effective fiber contents of more than 25%, and accordingly it has satisfactory strength, and there is less scattering of short fibers during knitting ~ processe~ or the like.
(3) The ends of the staple fibers constituting the spun yarn , .
of this invention exist inside and on the surface of the : .
yarn, and accordingly knitted and w~ven fabrics having high bulkiness, softness and warm hand feel can be , .
, manufacturedO
of this invention exist inside and on the surface of the : .
yarn, and accordingly knitted and w~ven fabrics having high bulkiness, softness and warm hand feel can be , .
, manufacturedO
(4) The spun yarn of this invention can be composed of non-crimped staple fibers, and accordingly a spun yarn can be manufactured having a smooth luster which cannot be attained using the conventional methods.
. :. .
. :. .
(5) The spun yarn of this invention can be composed of coil-crimped staple fibers, and accordingly a spun yarn can -- 19 -- .
: lV43~97 be manufactured having excellent bulkiness and stretch-ability which cannot be attained by the conventional methods.
: lV43~97 be manufactured having excellent bulkiness and stretch-ability which cannot be attained by the conventional methods.
(6) The spun yarn of this invention can be composed of at least two kinds of staple fibers, having less unevenness of blend in the radial and longitudinal directions of the spun yarn, and accordingly may exhibit the features of spun yarn obtained by blending different kind~ of fibers.
For instance, if differently colored fibers are blended, natural colors can be obtained, or if fibers of different shrinkage are blended, bulky yarn having uniform and - higher bulkiness can be manufactured, or if fibers of different fiber fineness are blended, higher bulkiness, softness and resilience can be obtained.
For instance, if differently colored fibers are blended, natural colors can be obtained, or if fibers of different shrinkage are blended, bulky yarn having uniform and - higher bulkiness can be manufactured, or if fibers of different fiber fineness are blended, higher bulkiness, softness and resilience can be obtained.
(7) Covered yarn obtained.~using this invention employs :.:
aontinuous multi-filam~nt yarn as a starting material -~ for the fibers composing the covering part thereof, and accordingly the fiber bundle composing the covering part : . . . .
has less unevenness of thicknesQ, and knitted and woven fabrics made therefrom have uniform surface, whiLe ;
the manufacture of knitted and woven fabrics can be conducted quite efficiently.
aontinuous multi-filam~nt yarn as a starting material -~ for the fibers composing the covering part thereof, and accordingly the fiber bundle composing the covering part : . . . .
has less unevenness of thicknesQ, and knitted and woven fabrics made therefrom have uniform surface, whiLe ;
the manufacture of knitted and woven fabrics can be conducted quite efficiently.
(8) According to the method of this invention, spun, blended, aovered or other yarn can be manufactured directly from - continuous multi-filament yarn, and this penmits ration-alization of the equipment, operating personnel and of ~-the necessary electric power supply.
(9) Because in the method of this invention, the cut points of each of the continuous filaments are randomly dispersed , : ~. . ..
~043197 inside and on the surface of yarn along the axial - direction of the yarn and the effective fiber contents of staple fibers in the spun yarn obtained are quite high, the spun yarn obtained has high strength and high uniformity of fineness, nap on the yarn surface and ~` high strength, and difficulties such as yarn breakage .: .
; in the manufacture of the spun yarn are reduced remarkably.
~043197 inside and on the surface of yarn along the axial - direction of the yarn and the effective fiber contents of staple fibers in the spun yarn obtained are quite high, the spun yarn obtained has high strength and high uniformity of fineness, nap on the yarn surface and ~` high strength, and difficulties such as yarn breakage .: .
; in the manufacture of the spun yarn are reduced remarkably.
(10) In the method of manufacturing blended spun yarn of this invention, the cut points of each of the continuous filaments are rand~mly dispersed inside and on the surface of yarn along the axial direction of the yarn and the staple fibers are blended with each other in the cross section of spun yarn, and accordingly difficulties such ; as yarn breakage in the manufacture of blended spun yarn are reduced remarkably.
(11) In the method of manufacturing the covered yarn of this invention, the covered yarn can be manufactured directly using the continuous multi-filament yarn in the prepara-. .
tion of the covering part and the other yarn for the - core part~ and m~reover covered yarn can be manufactured having in the covering fiber bundle an average number of fibers in cross section which is smaller than that ; obtained with the conventional methods so that the ., .,~
excellent properties of core yarn can be best exhibited.
tion of the covering part and the other yarn for the - core part~ and m~reover covered yarn can be manufactured having in the covering fiber bundle an average number of fibers in cross section which is smaller than that ; obtained with the conventional methods so that the ., .,~
excellent properties of core yarn can be best exhibited.
(12) In the method of manufacturing the doubled or two folded yarn of this invention, the cheese composed of the doubled yarn can be manufactured directly from the continuous multi-filament yarn. Accordingly, the process ' , , - . ' ' . . ., ' . ~ ', 1043~97 can be simplified remar~ably, and the doubled ob-tained has remarkably high uniformity, while the problem of yarn breakage in the spinning process can be almost completely avoided.
The features of this invention will be more apparent from the following examples.
Using the apparatus of Figure 1, continuous multifila-. . .~
ment yarn 2 is fed from the package 1 by the feed roller 3 into the cutter 4 and then through the delivery roller 5 into the twisting device 9, the twisted spun yarn 2b thus produced being ` taken up on the pirn 10.
" .
The cutter 4 is, as shown in Figure 2, equipped with ;~ the rough surface 4d which was prepared by electrically coating ` diamond powder of an average diameter of 20f~ onto the inner surface of the outlet of the hollow cylindrical rotary device 4a.
The cutter 4 was rotated in the direction of the arrow in Figure 1 and cut the continuQus multi-filament yarn 2 passing -~
through the hollow part into staple-like fibers to produce the fleece-like fiber bundle 2a.
- During this cutting operation, the straight and paral-lel state of the fibers composing the bundle was preferably maintained, and the fiber bundle 2a was discharged by the deli-very roller 5.
The above method was conducted by using polyester tex-tured yarn (150 deniers, 48 filaments), a surface speed of the first feed roller of 19.2 m/min. and the surface speed of the second feed roller of 20 m/min., a rotation of cutter 4 of 8,000 r.p.m. and a rotation of spindle 4c of 9,000 r.p.m.
: - 104319'7 he spun yarn obtained had a rate of yarn evenness, CV% of 6.9%, an average fiber length of fibers composing the yarn of 82 mm and a maxi~um fiber length of 210 mm.
."; .
For the purpose of comparison, a polyester textured yarn (150 deniers, 48 filaments), a polyester filament yarn (150 deniers, 48 filaments) and a spun yarn composed of poly-ester staple fibers (1.5 denier, 44 mm cut) manufactured 'according to the conventional method were prepared.
, . .
The rate of yarn evenness, CV, CV ~, and the speci-, .
` ~ 10 fic volume of the spun yarns thus obtained were measured.
; The specific volume was calculated from the diameter and yarn weight of cheese.
The test results are as follows:
Sample DV CV ~ Specific Volume spun yarn of this invention 6.9% 49 2.37 cc/g Filament yarn0.54 3.8 1.43 Polyester ~ex-tured yarn 1.05 7.3 1.87 ; spun yarn by con-ventional method 16.5 166 1.94 , The CV value of the spun yarn of this invention was 6.9% while that of the conventional spun yarn was 16.5%, and the CV ~ value of the spun yarn of this invention was remarkably lower than that of the conventional spun yarn, on the other hand, the specific volume of the spun yarn of this invention was 2.37 cc/g while that of the conventional spun yarn was 1.94 cc/g.
These test results show that the spun yarn of this invention has excellent bulkiness and uniformity.
Plain knittings of the abovementioned samples were con-.
ducted by means of a circular plain knitting machine of 28 guage.
1~43~97 With the oonventional spun yarn, yarn breakage occurred frequently and the knitted fabrics obtained had many defects The other yarns knitted smoothly and the knitted fabrics obtained thereby had no defects. Using knitted fabrics made from three - kinds of yarns other than the conventional spun yarn, shirts and blouses were sewn The knitted fabrics made from filament yarn . . .
or woolie yarn were not suitable because they had no feeling of thick cloth and they had the unpleasant feeling of sticking to - the skin, but the knitted fabrics made from spun yarn of this invention were quite suitable because they gave a feeling of soft-ness and of high quality of the surface.
The procedures in Example 1 were repeated but making changes in the speed ratio of the first feed roller 3 and the delivery roller 5, the position in which the cutter 4 was set, the inner diameter thereof, and the particle size of diamond powder therein.
For the purpose of comparison, the spun yarns thus . , .
obtained and three other kinds of spun yarns (sample ~os. 8 - 10) manufactured according to the conventional card and direct spinning systems were knitted-up by means of a circular plain knitting machine of 28 gauge.
The test results relating to efficiency of knitting, quality and hand feel of the knitted fabrics were as follows.
Sample Nos. 1, 3 and 10 were also tested in Example 1. ~
:
: . . . .
1~)43197 ,................................ . ..
; Sample CV cvr of _nittin~ qualityhfaeneld 1 1.05~ 7.3 0 0 X
2 6.1 43 0 0 0 3 6.9 49 0 0 0 - 4 8.3 58 O O O
; ~ 511.5 79 0 0 0 v^ 613.0 90 0 0 0 715.4 106 X ~ 0 811.9 113 0 0 X
`; 914.9 149 ~ ~ X
__ __ 16.5 1 166 X
. ,~ , . : :
In the table, 0 means excellent, ~ means good or allowable and X means bad. Sample No. 1 had excellent efficiency of knitting .: . ~ .
: and quality of the knitted fabrics but less bulkiness and softness . .
of surface. Sample NosO 8 - 10 were knittable insofar as a small ,~ . .
amount of knitted fabric could be obtained but had poorer quality and hand feel.
Using the process illustrated in Figure 7, and using woolie polyester filament yarn (150 deniers, 72 filaments) as the continuou-q multi-filament yarn for the covering part and polyure-thane elastic yarn (30 deniexs) as the yarn for the core part, a - covered yarn was manufactured.
the surface speed of feed roller 3 13.1 m/min.
the surface speed of delivery roller 5 1308 m/min.
the roller speed of third feed roller 13 5.5 m/min.
,': ' .:
;
. ' .
., ~ .
~. ..... . .
`.~, 1~431g'~
the rotation speed of spindle 11,000 rpm the rotation speed o~ cutter 5,500 rpm The covered yarn thus obtained had excellent uniformity and stretchability and the covering portion was of good quality.
Using the process illustrated in Figure3 8 and 9, ;` doubled yarn was manufactured.
The continuous multi-filament yarn was woolie polyester yarn (150 deniers, 48 filaments) and the surface speed of the feed roller 3 was 19.2 m/min.
The surface speed of the delivery roller 5 was 20 m/min.
The cutter 4 had electrically coated diamond powder of 800 mesh on the inner surface 4d and had an inner diameter of 10 mm. The rotation speed of the cutter was 6,ooo rpmO
The rotation speed of the pot 17 was 8,ooo rpm~
The doubled yarn thus obtained had excellent uniformity and fineness. There was no yarn brea~age in the spinning process.
':
''-:
. .
' '' . ,.
.
.. ' . . ' :
The features of this invention will be more apparent from the following examples.
Using the apparatus of Figure 1, continuous multifila-. . .~
ment yarn 2 is fed from the package 1 by the feed roller 3 into the cutter 4 and then through the delivery roller 5 into the twisting device 9, the twisted spun yarn 2b thus produced being ` taken up on the pirn 10.
" .
The cutter 4 is, as shown in Figure 2, equipped with ;~ the rough surface 4d which was prepared by electrically coating ` diamond powder of an average diameter of 20f~ onto the inner surface of the outlet of the hollow cylindrical rotary device 4a.
The cutter 4 was rotated in the direction of the arrow in Figure 1 and cut the continuQus multi-filament yarn 2 passing -~
through the hollow part into staple-like fibers to produce the fleece-like fiber bundle 2a.
- During this cutting operation, the straight and paral-lel state of the fibers composing the bundle was preferably maintained, and the fiber bundle 2a was discharged by the deli-very roller 5.
The above method was conducted by using polyester tex-tured yarn (150 deniers, 48 filaments), a surface speed of the first feed roller of 19.2 m/min. and the surface speed of the second feed roller of 20 m/min., a rotation of cutter 4 of 8,000 r.p.m. and a rotation of spindle 4c of 9,000 r.p.m.
: - 104319'7 he spun yarn obtained had a rate of yarn evenness, CV% of 6.9%, an average fiber length of fibers composing the yarn of 82 mm and a maxi~um fiber length of 210 mm.
."; .
For the purpose of comparison, a polyester textured yarn (150 deniers, 48 filaments), a polyester filament yarn (150 deniers, 48 filaments) and a spun yarn composed of poly-ester staple fibers (1.5 denier, 44 mm cut) manufactured 'according to the conventional method were prepared.
, . .
The rate of yarn evenness, CV, CV ~, and the speci-, .
` ~ 10 fic volume of the spun yarns thus obtained were measured.
; The specific volume was calculated from the diameter and yarn weight of cheese.
The test results are as follows:
Sample DV CV ~ Specific Volume spun yarn of this invention 6.9% 49 2.37 cc/g Filament yarn0.54 3.8 1.43 Polyester ~ex-tured yarn 1.05 7.3 1.87 ; spun yarn by con-ventional method 16.5 166 1.94 , The CV value of the spun yarn of this invention was 6.9% while that of the conventional spun yarn was 16.5%, and the CV ~ value of the spun yarn of this invention was remarkably lower than that of the conventional spun yarn, on the other hand, the specific volume of the spun yarn of this invention was 2.37 cc/g while that of the conventional spun yarn was 1.94 cc/g.
These test results show that the spun yarn of this invention has excellent bulkiness and uniformity.
Plain knittings of the abovementioned samples were con-.
ducted by means of a circular plain knitting machine of 28 guage.
1~43~97 With the oonventional spun yarn, yarn breakage occurred frequently and the knitted fabrics obtained had many defects The other yarns knitted smoothly and the knitted fabrics obtained thereby had no defects. Using knitted fabrics made from three - kinds of yarns other than the conventional spun yarn, shirts and blouses were sewn The knitted fabrics made from filament yarn . . .
or woolie yarn were not suitable because they had no feeling of thick cloth and they had the unpleasant feeling of sticking to - the skin, but the knitted fabrics made from spun yarn of this invention were quite suitable because they gave a feeling of soft-ness and of high quality of the surface.
The procedures in Example 1 were repeated but making changes in the speed ratio of the first feed roller 3 and the delivery roller 5, the position in which the cutter 4 was set, the inner diameter thereof, and the particle size of diamond powder therein.
For the purpose of comparison, the spun yarns thus . , .
obtained and three other kinds of spun yarns (sample ~os. 8 - 10) manufactured according to the conventional card and direct spinning systems were knitted-up by means of a circular plain knitting machine of 28 gauge.
The test results relating to efficiency of knitting, quality and hand feel of the knitted fabrics were as follows.
Sample Nos. 1, 3 and 10 were also tested in Example 1. ~
:
: . . . .
1~)43197 ,................................ . ..
; Sample CV cvr of _nittin~ qualityhfaeneld 1 1.05~ 7.3 0 0 X
2 6.1 43 0 0 0 3 6.9 49 0 0 0 - 4 8.3 58 O O O
; ~ 511.5 79 0 0 0 v^ 613.0 90 0 0 0 715.4 106 X ~ 0 811.9 113 0 0 X
`; 914.9 149 ~ ~ X
__ __ 16.5 1 166 X
. ,~ , . : :
In the table, 0 means excellent, ~ means good or allowable and X means bad. Sample No. 1 had excellent efficiency of knitting .: . ~ .
: and quality of the knitted fabrics but less bulkiness and softness . .
of surface. Sample NosO 8 - 10 were knittable insofar as a small ,~ . .
amount of knitted fabric could be obtained but had poorer quality and hand feel.
Using the process illustrated in Figure 7, and using woolie polyester filament yarn (150 deniers, 72 filaments) as the continuou-q multi-filament yarn for the covering part and polyure-thane elastic yarn (30 deniexs) as the yarn for the core part, a - covered yarn was manufactured.
the surface speed of feed roller 3 13.1 m/min.
the surface speed of delivery roller 5 1308 m/min.
the roller speed of third feed roller 13 5.5 m/min.
,': ' .:
;
. ' .
., ~ .
~. ..... . .
`.~, 1~431g'~
the rotation speed of spindle 11,000 rpm the rotation speed o~ cutter 5,500 rpm The covered yarn thus obtained had excellent uniformity and stretchability and the covering portion was of good quality.
Using the process illustrated in Figure3 8 and 9, ;` doubled yarn was manufactured.
The continuous multi-filament yarn was woolie polyester yarn (150 deniers, 48 filaments) and the surface speed of the feed roller 3 was 19.2 m/min.
The surface speed of the delivery roller 5 was 20 m/min.
The cutter 4 had electrically coated diamond powder of 800 mesh on the inner surface 4d and had an inner diameter of 10 mm. The rotation speed of the cutter was 6,ooo rpmO
The rotation speed of the pot 17 was 8,ooo rpm~
The doubled yarn thus obtained had excellent uniformity and fineness. There was no yarn brea~age in the spinning process.
':
''-:
. .
' '' . ,.
.
.. ' . . ' :
Claims (23)
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A spun yarn composed of staple fibers only and having the average number of fibers in cross section N, and the rate of yarn evenness, CV, being such that the inequality is obeyed.
2. A spun yarn according to claim 1, in which the effective fiber content of the staple fibers is more than 25%.
3. A spun yarn according to claim 1, in which the ends of each individual staple fiber exist inside and on the surface of the yarn.
4. A spun yarn according to claim 1, in which the staple fibers are non-crimped staple fibers.
5. A spun yarn according to claim 1, in which the staple fibers are coil-crimped staple fibers.
6. A spun yarn according to claim 1, in which the spun yarn is composed of at least two kinds of staple fibers.
7. A spun yarn according to claim 6, in which the different kinds of staple fibers are blended with each other in the cross section of the yarn.
8. A spun yarn according to claim 6, in which the respective average number of fibers of each different kind of fiber in cross section, N1, N2, ..........., and the respective rate of yarn evenness of each different kind of fiber, CV1, CV2, ......, are such that they obey the inequalities
9. A composite yarn composed of a staple fiber bundle and another yarn, and having the average number of fibers in cross section, N, and the rate of yarn evenness, CV, of the staple fiber bundle such that the inequality is obeyed.
10. A composite yarn according to claim 9, in which the said other yarn comprises the core part of a covered yarn.
11. A composite yarn according to claim 10, in which the other yarn is an elastic yarn.
12. A method for manufacturing a spun yarn which comprises contacting substantially non-twisted continuous multi-filament yarn, fed from a feed roller, with a cutter moving approximately at right angles to the yarn axis to cut it into staple while maintaining the continuity of fiber bundle, discharging the cut fiber bundle from a delivery roller rotating at a surface speed approximately equal to the surface speed of the feed roller, and then gathering and taking up the fiber bundle.
13. A method for manufacturing spun yarn according to claim 12, in which the ratio of the surface speed of the delivery roller to that of the feed roller is between 1.01 to 1.20.
14. A method for manufacturing spun yarn according to claim 12, in which the bending angle of the continuous multi-filament yarn presented in contact with the cutter is between 15° to 45°.
15. A method for manufacturing spun yarn according to claim 12, in which the cutter comprises a hollow cylindrical rotary device and the continuous multi-filament yarn is cut by contacting it with the inner surface of the hollow cylindrical rotary device.
16. A method for manufacturing spun yarn according to claim 15, in which the rotation speed of the hollow cylindrical rotary device is more than 1,000 rpm.
17. A method for manufacturing spun yarn according to claim 12, in which at least two kinds of substantially non-twisted continuous multi-filament yarns are supplied.
18. A method for manufacturing spun yarn according to claim 12, in which the substantially non-twisted continuous multi-filament yarn is non-crimped yarn.
19. A method for manufacturing spun yarn according to claim 12, in which the substantially non-twisted continuous multi-filament yarn is spiral-crimped yarn.
20. A method according to claim 12 modified in that the cut fiber bundle is united with a separately supplied yarn at the delivery roller so as to obtain a composite yarn.
21. A method according to claim 20 wherein the said separately supplied yarn is supplied in a more stretched condition than the cut fiber bundle.
22. A method for manufacturing covered yarn according to claim 21, in which the separately supplied yarn is elastic yarn.
23. A method for manufacturing spun yarn which comprises contacting substantially non-twisted continuous multi-filament yarn, fed from a feed roller, with a cutter moving approximately at right angles to the yarn axis to cut it into staple while maintaining the continuity of said fiber bundle, delivering the cut fiber bundle from a delivery roller rotating at an approximately same surface speed as the surface speed of the feed roller, intro-ducing the cut fiber bundle into a pot rotating at a high speed so as to twist it, and when the yarn content in the pot reaches a predetermined level, doubling the yarn in the pot and the yarn continuously coming into said pot, twisting doubled yarn and taking it up.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA255,621A CA1043197A (en) | 1976-06-24 | 1976-06-24 | Spun yarn and process for manufacturing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA255,621A CA1043197A (en) | 1976-06-24 | 1976-06-24 | Spun yarn and process for manufacturing the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1043197A true CA1043197A (en) | 1978-11-28 |
Family
ID=4106279
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA255,621A Expired CA1043197A (en) | 1976-06-24 | 1976-06-24 | Spun yarn and process for manufacturing the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1043197A (en) |
-
1976
- 1976-06-24 CA CA255,621A patent/CA1043197A/en not_active Expired
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