CA1108833A - Spun-like yarn with variable denier filaments - Google Patents

Spun-like yarn with variable denier filaments

Info

Publication number
CA1108833A
CA1108833A CA331,411A CA331411A CA1108833A CA 1108833 A CA1108833 A CA 1108833A CA 331411 A CA331411 A CA 331411A CA 1108833 A CA1108833 A CA 1108833A
Authority
CA
Canada
Prior art keywords
yarn
values
filaments
small values
large values
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA331,411A
Other languages
French (fr)
Inventor
Wayne T. Mowe
John R. Dees
Lawrence E. Blackmon
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monsanto Co
Original Assignee
Monsanto Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=25447827&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA1108833(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Monsanto Co filed Critical Monsanto Co
Application granted granted Critical
Publication of CA1108833A publication Critical patent/CA1108833A/en
Expired legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/20Formation of filaments, threads, or the like with varying denier along their length
    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0206Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
    • D02G1/024Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting with provision for imparting irregular effects to the yarn
    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0206Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
    • D02G1/0246Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting at least some of the filaments being simultaneously broken or cut, e.g. by stretching or abrading
    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0286Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist characterised by the use of certain filaments, fibres or yarns

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Artificial Filaments (AREA)

Abstract

SPUN-LIKE YARN WITH VARIABLE DENIER FILAMENTS
ABSTRACT OF DISCLOSURE
A yarn having variable denier filaments with thick and thin regions is drawn at a draw ratio selected to break filaments in the thin regions. This may be done while false-twist texturing. The resulting broken ends protrude from the yarn, giving a spun-like yarn.

Description

SPUN-LIKE YARN WITH VARIABLE DENIER FILAMENTS
SPECIFICATION
The invention relates to novel processes for making from a yarn consisting of essentially continuous filaments a yarn simulating one spun from staple fibers.
It is known to treat certain types of continuous ~ilament yarns by various processes to Produce yarns which simulate to some degree yarns spun from staple fibers.
Typlcal prior art processes which break ~he fllamen~s so as to leave the broken ends protruding from the yarn bundle are Heinrich U.S. patent 3,857,232; Cardinal U.S. patent 3,857,233; and Yasuzuka U.S. patent 3,967,441, the disclosures of which are incorporated herein by reference. Fairley British Specification 971,573 discloses a similar process wherein the broken filament ends are stated to be entangled within the yarn bundle, rather than protruding from the bundle.
In each of these and o-ther known processes wherein filaments are broken, the breakable filaments are substantially unlform from end to end. That is, there is made no provision for preferred locations of breakage along the breakable filaments, and hence, less control of breakage than might be desired.
According to the present invention, ~his and other difficulties in the prior art are avoided by using a feed yarn having preferred locations for breakage along the breakable filaments.
According to a first major aspect of the invention, there is provided a process for making a spun-like yarn comprising drawing a feed yarn, the f~ed yarn comprising a plurality of continuous filamen~s, each of this pIurality of .
, ~ ~' ..;; ' .

' A~

filaments having a cross-sectional area which varies repetitively from small values in thin regions to large values in thick regions along its length, ~he large values being at least 25% greater than the small values, the thick and thin regions being out of phase from filament: to filament along the length o the yarn, the filaments being repeatedly broken to provide broken ends primarily in the thin regions, the broken ends protruding from the bundle.
According to another aspect of the invention, the yarn is false-twisted while being drawn.
According to another aspect of the invention, the yarn is false-twisted and heat-set while being drawn.
According to another aspect of the invention, the average distance between consecutive thick portions along each of the filaments is between 2 centimeters and 20 meters, and preferably between 20 centimeters and 5 meters.
According to another aspect o~ the invention, the large area values are at least 100% greater than the small area values, and preferably are between 300% and 500% of the small area values.
Other aspects of the invention are in part set forth below and will in part be obvious from the following descrip-tion taken in connection with the accompanying DRAWINGS
wherein:
FIGURE 1 is a vertical sectional view of the preferred embodiment of a spinneret usable to malce the feed yarns according to the invention;
FIGURE 2 is a bottom plan view of the FIGURE 1 spinneret, looking up;
FIGURE 3 is a cross-sectional view o a filament according to certain aspects of the invention;
FIGURE ~ is a side elevation view of the molten streams issuing from the FIGURE 1 spinneret according to certain aspects of the invention;
FIGURE 5 is a graph illustrating the variation ;.n denier along a representative filament according to certa n aspects of the invention; and FIGURE 6 is a graph illustrating the dis~ribution of the rluctuations illustrated in FIGURE 4 for a representative , , :.
~, : , , multiple orifice spinneret according to certain aspects of ~he inventlon .
Preparation of ~xemplary Feed Yarn The feed yarn for the process invention will be specifically exemplified using polyester polymer, it being understood that certain aspec~s of the :invention are applicable to the class of melt-spinnable polymers generally.
"Polyes~er" as used herein means fiber-:Eorming polymers at least 85~/o by weight of which is formable by reacting a dihydric alcohol with tereph~halic acid. Polyester ~ypically is formed either by direct esterification of ethylene glycol with terephthalic acid, or by ester interchange between ethyLene glycol and dimethylterephthalate.
FIGURES 1 and 2 illustrate the preferred embodiment of a spinneret design which can be employed for obtaining all aspects of the invention. The spinneret includes a large counterbore 20 formed in the upper surface 21 Oe spinneret plate 22. Small counterbore 24 is formed in the bottom o and at one side of large counterbore 20. A large capillary 26 extends from the bottom of large counterbore 20 at the side opposite small counterbore 24, and connects the bottom of large counterbore 20 with the lower surface 28 of plate 22.
Small capillary 30 connects the bottom of counterbore 24 with surface 28. Capillaries 26 and 30 are each inclined four degrees from the vertical, and th~ls have an included angle of eight degrees. Counterbore 20 has a diameter of 0.113 inch t2.87 mm.), while counterbore 24 has a diameter of 0.052 inch (1.32 mm.). Capillary 26 has a diameter of 0.016 inch (0.396 mm.) and a length of 0.146 inch (3.81 mm.), while capillary 30 has a diameter of 0.009 inch (0.229 mm.) and a length of 0.032 inch (0.813 mm.). Land 32 separates capillaries 26 and 30 as they emerge at surface 28, and has a width of 0.0043 inch (0.108 mm.). Plate 22 has a thickness of 0.554 inch (14.07 mm.). Capillaries 26 and 30 together with counterbore 20 and Z4 constitute a combined orifice for spinning various novel and useful filaments according to the invention, as will be more particularly described hereinafter.
As a specific example, molten polyester polymer of normal textile molecular weight is metered at a temperature ,..:

:

of 290C. through a spinneret having 34 combined orifices as above specifically disclosed. The polymer throu~hput is adjusted to produce filaments of 8 average denier per filament at a spinning speed of 3400 yards per minute, the molten stream~s being conventionally quenched into filaments by transversely directed quenching air.
Under these spinning conditions a remarkable phenomenon occurs, as illustrated in FIGURE 4. Due to the geometry of the spinneret constrwction, the polymer flowing through the smaller capillaries 30 has a higher velocity than that flowing through the larger capillaries. The speeds and momenta of the paired streams issuing from each combined orifice and the angle at which the streams converge outside the spinneret are such that the slower streams 34 travel in substantially straight lines after ~he points at which the paired streams first touch and attach, while each of the smaller and faster of the streams 36 forms sinuous loops back and forth between successive points of attachment 38 with its associated larger streams. This action can be readily obser~ed using a stroboscopic light directed onto the streams immediately below the spinneret face 28. As the molten streams accelerate away from the spinneret, the slower stream attenuates between the points of a~tachment 38 and the loops o~ the faster stream become straightened until the faster stream is brought into continuous contact with the slower stream: The slower stream attenuates more between the points of first attachment than at the points of first attachment so that the resulting combined stream has a cross-section which is larger at the points of first attachment than 3g in the regions between these points. The resulting combined stream is then further a~tenuated somewhat until it is solidified into a filament 40 by the transverse quench air.
Each solidified filament 40 has non-round cross-sectional areas which vary repetitively along its length.
As illustrated qualitatively in FIGURE 5, when using the above spinning conditions, the filament cross-sectional area repetitively varies at a repetition rate of about one per meter, although this can be varied by modifying the spinning conditions and the geometry of the spinneret passages.
:..

-s -Due to minor differences between combined orifices, temperature gradations across the spinneret, and other like deviations from exactly the same treatment for each pair of streams, a multiple orifice spinneret will typically provide somewhat different repetition rates among the several result-ing streams and filaments. An example of this is qualitatively shown in FIGURE 6, whereirl is sho~n that various orifices produce somewhat different repetition rates as determined by stroboscopic examination of the combined streams just below the spinneret face. In the resulting multifilament yarn, each filament has a cross~sectional area which varies repetitively from small values in thin regions to large values in thick regions along its length, the large values being at least 25% greater than the small values.
Improved spun like effects in the ultimate te~tured yarn are obtained when the large values are at least 100% greater than the small values, with optimum results when the large values are between 300% and 500% of the small values.
An Exemplary Process of the Invention The above feed yarn is simultaneously draw-textured on a Barmag FK-4 texturing machine, using as the false-twist device a friction aggregate of the type disclosed in Yu U.S. patent 3,973,383, the disclosure of which is incorporated herein by reference. The draw ratio is set a~ 1.60 with a winding speed of 385 ypm (about 350 meters per minute~. Both heaters are set at 200C., with an overfeed to the second heater of 10.47% and an overfeed to the winder of 6.79%.
The aggregate speed is set such that the yarn tensions just before and just after the aggreOate are equal.
The resulting yarn has numerous filament breaks primarily in the thin regions, the broken ends protruding from the yarn bundle. The filaments are broken with consider-ably more control than those in the patents referred to above, and, because of the variable denier, fabrics made from the resulting yarns have a much more soft and luxurious hand than those made from prior art yarns with the same average denier per filament. This softness of hand is particularly evident when the cross-sectional areas of the thick portions of the ;;

filaments are at least 100% greater than those of the thin portions, and values between 300% and 500% greater are particularly preferred.

. , -. ..

.; . . . .

.
. , - - . . . .

Claims (13)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A yarn bundle characterized by a plur-ality of quasi-continuous filaments, each of said plurality of filaments having a cross-sectional area which varies repetitively from small values in thin regions to large values in thick regions along its length, said large values being at least 25% greater than said small values, said thick and thin regions being out of phase from filament to filament along the length of said yarn, said filaments being repeatedly broken to provide broken ends primarily in said thin regions, said broken ends protruding from said bundle.
2. The yarn bundle of claim 1, characterized in that said filaments have alternating S and Z helical crimp along their lengths.
3. The yarn bundle of claim 1, characterized in that the average distance between consecutive thick regions along each of said filaments is between 2 centi-meters and 20 meters.
4. The yarn bundle of claim 3, characterized in that said average distance is between 20 centimeters and 5 meters.
5. The yarn bundle of claim 1, characterized in that said large values are at least 100% greater than said small values.
6. The yarn bundle of claim 2, characterized in that said large values are at least 100% greater than said small values.
7. The yarn bundle of claim 1, characterized in that said large values are between 300% and 500% of said small values.
8. The yarn bundle of claim 2, characterized in that said large values are between 300% and 500% of said small values.
9. A process for making a spun-like yarn, characterized by drawing a feed yarn, said feed yarn comprising a plurality of continuous filaments, each of said plurality of filaments having a cross-sectional area which varies repetitively from small values in thin regions to large values in thick regions along its length, said large values being at least 25%
greater than said small values, said drawing being at a draw ratio selected to break a plurality of said fila-ments in said thin regions.
10. The process of claim 9, characterized in that said yarn is false-twisted while said yarn in being drawn.
11. The process of claim 9, characterized in that said yarn is false-twisted and heat-set while said yarn is being drawn.
12. The process of claim 9, characterized in that said large values are at least 100% greater than said small values.
13. The process of claim 12, characterized in that said large values are between 300% and 500% of said small values.
CA331,411A 1978-07-10 1979-07-09 Spun-like yarn with variable denier filaments Expired CA1108833A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US92293778A 1978-07-10 1978-07-10
US922,937 1978-07-10

Publications (1)

Publication Number Publication Date
CA1108833A true CA1108833A (en) 1981-09-15

Family

ID=25447827

Family Applications (1)

Application Number Title Priority Date Filing Date
CA331,411A Expired CA1108833A (en) 1978-07-10 1979-07-09 Spun-like yarn with variable denier filaments

Country Status (8)

Country Link
EP (1) EP0007725B2 (en)
JP (1) JPS5516990A (en)
AU (1) AU528268B2 (en)
CA (1) CA1108833A (en)
DE (1) DE2967197D1 (en)
ES (1) ES482359A1 (en)
IL (1) IL57811A0 (en)
ZA (1) ZA793442B (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4720314A (en) * 1980-06-06 1988-01-19 Celanese Corporation Process for producing self-crimping polyester yarn
US4562029A (en) * 1980-06-06 1985-12-31 Celanese Corporation Self-crimping polyester yarn
US4376743A (en) * 1981-06-12 1983-03-15 Fiber Industries, Inc. Melt spinning process
US4364998A (en) * 1981-07-20 1982-12-21 E. I. Du Pont De Nemours And Company Spunlike yarns
JPS60224808A (en) * 1984-04-16 1985-11-09 Teijin Ltd Manufacture of bulky composite yarn

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB971573A (en) * 1962-08-14 1964-09-30 British Nylon Spinners Ltd Improvements in or relating to the manufacture of bulked yarns
US4000960A (en) * 1972-08-04 1977-01-04 Mitsubishi Rayon Co., Ltd. Apparatus for manufacturing synthetic tow for stretch-cut spinning process
US4084622A (en) * 1975-06-11 1978-04-18 Toray Industries Inc. Textured polyester yarns and process for the production thereof
GB1535057A (en) * 1975-12-11 1978-12-06 Toray Industries Multifilament yarn of irregular cross section filaments or fibres and method of manufacture

Also Published As

Publication number Publication date
IL57811A0 (en) 1979-11-30
ZA793442B (en) 1980-11-26
EP0007725B1 (en) 1984-08-29
JPS6330403B2 (en) 1988-06-17
JPS5516990A (en) 1980-02-06
AU528268B2 (en) 1983-04-21
EP0007725B2 (en) 1988-11-02
EP0007725A1 (en) 1980-02-06
AU4877679A (en) 1980-01-17
ES482359A1 (en) 1980-04-01
DE2967197D1 (en) 1984-10-04

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