CN100392163C - Stretch break method and product - Google Patents

Stretch break method and product Download PDF

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Publication number
CN100392163C
CN100392163C CNB008114129A CN00811412A CN100392163C CN 100392163 C CN100392163 C CN 100392163C CN B008114129 A CNB008114129 A CN B008114129A CN 00811412 A CN00811412 A CN 00811412A CN 100392163 C CN100392163 C CN 100392163C
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China
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fiber
zone
yarn
filament
length
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CNB008114129A
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Chinese (zh)
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CN1561413A (en
Inventor
J·A·佩罗托
P·波佩
G·E·西蒙斯
A·S·谭
D·C·维瑟
W·C·瓦尔克
J·L·琼斯
P·阿茨特
H·米勒
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纳幕尔杜邦公司
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Priority to US13909699P priority Critical
Priority to US60/139,096 priority
Application filed by 纳幕尔杜邦公司 filed Critical 纳幕尔杜邦公司
Publication of CN1561413A publication Critical patent/CN1561413A/en
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Publication of CN100392163C publication Critical patent/CN100392163C/en

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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01GPRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G1/00Severing continuous filaments or long fibres, e.g. stapling
    • D01G1/06Converting tows to slivers or yarns, e.g. in direct spinning
    • D01G1/08Converting tows to slivers or yarns, e.g. in direct spinning by stretching or abrading

Abstract

A method for stretch breaking fibers to produce a staple yarn and operating a staple fiber spinning machine that enables the production of a plurality of products of lot size smaller than a large denier tow product. The process includes at least two break zones and a consolidation zone downstream from a second break zone to form a staple yarn. The filaments are broken in a second break zone downstream from the first break zone by increasing the speed of the fiber fed into the process.

Description

Stretch break method and product

The application claims that enjoying in the 1999.06.14 application serial is that 60/139,096 title is the priority of the provisional application of " stretch break method and product ".

Technical field

The present invention relates generally to a kind of transformation and spinning technique of fiber, and relating in particular to continuous filament fiber broken becomes discontinuous filament fiber and these consolidated fibers are become method of yarn.

Technical background

The spinning of synthetic staple was once produced like this, and continuous filament yarn is cut into staple fibre then and synthetic threads, and its mode is identical with cotton fiber or wool fibre.Better simply direct spinning technique also is used, wherein parallel continuous filament yarn is broken and being called as sometimes between feeding roller and outlet roller broken drawing-off formation discontinuous fibre bar in district or the crush cutting district, twisting forms the yarn of spinning then, the US 2 that is authorizing New for example, 721,440 or authorize the US2 of Preston, 784,458 disclosed like that.This previous technology is carried out slowly, because be subjected to the restriction of real twisting apparatus inherent speed.As substituting of real twisting, people such as Bunting are at US 3,110, once disclose available a kind of entanglement in 151, and the air jet system of promptly entwining tangles into fixed staple fibre yarn and makes yarn product.This product can be produced soon than real twisting, but in intensity, cleaning and evenly not as good as the yarn of tradition spinning.In addition, authorize people's such as Adams US 4,080,778 once disclosed a kind of technology, can be with the heating of continuous filament yarn tow and the stretching at 1500-5000 dawn, in single section, break and drawing-off then, keep the co-flow of gas and fiber to pass through the niproll jaw to eject by drawing roller with holes and suction silk device at a high speed.Under spraying, the entanglement of the disclosed the sort of pattern of Bunting make discontinuous unconsolidated long filament fixed and make the yarn at 50-300 dawn then.Electrostatic charge break with draw zone in be removed to reduce opening of fiber.The static removal device be set at transport the roller of long filament by flow process near.The length of nearly 1.5-20% surpasses 76cm in the discontinuous long filament of breaking district's generation.Yarn axis need remain on vertical direction in whole flow process.The fixed yarn of the product that obtains like this has the good intensity that generally is higher than ring ingot slubbing yarn, and clean and do not have a slubbing.

Once illustrated in the US 4,924,556 that authorizes Gilhaus that available a plurality of district that breaks reduced the length that the big dawn counts the discontinuous long filament of tow gradually, it is by tension force yarn guiding chase comb and guide be combined into by several low heavy tow that this big dawn is counted tow.The low like this tow that heavily feeds can be used less than 4.5 twisted operation and keeps high productive capacity.In conjunction with the twisted and thermal treatment zone (I district) of tow on a level height in be stretched and rupture, move through successively then one or more shorten gradually break break district (II-V district), these are distinguished and flatly are arranged on another height with the saving ground space.Break the district and can have one or more " mainly " fracture zone fiber is shortened gradually, and one or more fracture zones of setting average fiber length and setting fiber length varies rate (%cv).The strand that forms can be processed (so that carrying subsequently), heat treatment and be collected in jar tube in a winding mechanism.Strand is expected further processed, as in a spinning machine, so that produce the yarn of Denier.Said process can be handled the feeding tow that every long filament is 3.0 dawn fiber numbers, and is breaking district's insied width greater than 110 of 270mm, 000-220, the broadband at 000 dawn.In the example shown in this patent Fig. 1, the first preliminary fracture zone is the II district, is at least 500mm length, and the filament length that causes in this district has " near the normal distribution " of a fibre length from several millimeters to the II section length.The length in II district can be avoided the flocculate fracture for the long length that can reduce disruptive force at one and one and improve optimal value between the short length of operating condition.Also having one second preliminary fracture zone is the III district, and this district is at least 200mm but is not more than 1000mm, is " quite short " compared with the II district.Next also having first fracture zone is the IV district, can set average fiber length and seem shorter than the III district; With second fracture zone be the V district, can eliminate long fiber, set the rate of change (is feature with %cv) of fibre length, and seem and lack than IV district.In the V district, " can cause the twisted of fracture " (being considered to is exactly speed ratio) is at least the twisted twice of fracture in the IV district.

People such as Minorikawa are at US 4,667, illustrate once that a kind of online technological process of level can be used to make wrapped yarn from fibre bundle in 463.This flow process comprise drawn tow make it by heater, draft-cut tow in the narrow long and narrow zone of width and the fiber that makes draft-cut through overcorrection draft-cut work step and yarn shaping work step.The length of correcting draft-cut work step section is about 0.4 to 0.9 times of draft-cut section length, and the extensibility of correcting draft-cut is at least 2.5 times.Stretch and preferably carry out in two stages so that reach the maximum tension rate of 90-99%, the fiber of stretching is then by heat treatment.Yarn shaping work step uses a kind of spraying system to cause wrapper fibre and thereby their loopings are made consolidated fibers on core part fiber around fiber core.In correcting draft-cut section and yarn shaping section, use apron to bring occasionally and adjust peripheral fiber.Authorizing the U.S.4 of Minorikawa, 356, the feature of illustrated this product is in 690, in yarn more than the length of about 15% long filament less than 0.5 times of yarn average filament length, and length more than about 15% long filament is arranged greater than 1.5 times of yarn average filament length.In the example shown, the maximum output speed of the flow process of the yarn of manufacturing 174 to 532 dawn (30.5 to 10 yarn count) is 200 meters/minute (examples 6), and most of examples are to move under about 100 meters/minute speed.

The problem that exists with products that the people produced such as Adams is, surpass 76cm in the length of the single discontinuous long filament of breaking the 1.5-20% that produces in the district and can further add the problem that takes place man-hour (mainly being that looping is on roller), particularly when selected process be not when being orientated in vertical direction.It is that it can limit the filament end number that can stretch out from yarn that long filament in the product of Adams also has a problem, and this filament end can provide good hand feeling and outward appearance at yarn during as textiles.

Under the situation of the horizontal alignment of Gilhaus, may be when the big tow of processing, to adopt easily, can between discontinuous long filament, produce good bundle internal friction because it is believed that a large amount of long filaments, therefore can keep the globality of tow during the course not difficultly.And under the situation of Adams, the few filaments in unconsolidated discontinuous yarn still can only provide very little friction cohesiveness.To it is believed that in order eliminating and to be necessary before yarn does not also have fixed enhancing, to adopt vertical orientation owing to gravity acts on the side force that causes on the weak yarn.

Adams proposes all and breaks and finish in a section, and any drawing-off is also carried out in same section.This many purposes section makes final yarn parameter be difficult to maybe can not optimize respectively.

People such as Minorikawa may have problem on the discontinuous long filament of control, use the apron band to testify from it.Control of this shortage and like that promptly 200 meters/minute of using the apron band its flow process rate limit may be enumerated in its example, the commercial production line that this speed is counted yarn for the single low dawn is too slow.

The US 4,118,921 that grants people such as Adams disclose a kind of by directly " spinning technology be entangled to subsequently one less than on 50 millimeters the pin by good intensity, sophistication and the inhomogeneity non-twist short fiber yarn of having of continuous long filament production.To break the fiber that becomes to have 18 to 60 centimetres of average lengths less than the long filament of 70% fracture elongation, wherein have at least 5% staple fibre, at least 1.5% long fiber and 50% to 93.5% the fiber of length between 12.7 to 76 centimetres.

Grant DE 3926930 A of Gilhaus 1A kind of fracture transforming machine is disclosed, be converted into chemical fibre strip in order to fracture with the thick comet of chemical fibre, corresponding to pre-fracture head and fracture head, have two in all cases and drive the transmission tube, be their selected hydraulic load, the pressure roller that freely rotates, between them, the thick comet of chemical fibre that be processed is transmitted in the mode of stressed locking.For reducing the slippage of pre-fracture head and fracture head, the peripheral speed longshore current journey direction of the suggestion second transmission tube greater than the peripheral speed of the peripheral speed of the first transmission tube and/or the pressure roller in the clamping range between the pressure roller and the second transmission tube along the peripheral speed of this flow direction greater than the first transmission tube in the pressure limit between the pressure roller and the first transmission tube.

Therefore need an improvement flow process that is used for producing the stretch break method yarn, operating parameter can be optimised independently in this flow process, this flow process is not limited in vertical orientated down operation, and can from endless tow, separate, looping on process equipment and the long filament that limits the undue length of filament end number in the yarn can not exist.Need a flow process can be soundly under the high speed more than 250 meters/minute operation in case make can be directly from tow once form yarn, economically can attracting production line.

Summary of the invention

The applicant etc. once developed a kind of technological process, can from continuous long filament feeding yarn produce that filament length is shorter than about 64cm (25 inches) thus, Denier, discontinuous filament yarn can make per inch have filament end more than the number.New technological flow can under high speed, move make single yarn production in viable commercial, its productivity ratio substantially exceeds per inch traditionally and has many production of staple fiber yarns rates filament end, RING SPINNING of number.This flow process allows to adopt orientation operation vertical or level and can not damage performability.This flow process is applicable to multiple continuous filament yarns polymer and can be used to mix continuous filament yarns inequality.In more excellent embodiment, this flow process uses at least two fracture zones to make average filament length greater than 6.0 inches so that obtain more excellent filament length in final yarn product, and the speed ratio D1 of first fracture zone and the speed ratio D2 of second fracture zone should reach 2.0 the level of being at least.In addition, the ratio of the second fracture zone length L 2 and the first fracture zone length L 1 should be limited in 0.2 to 0.6 the scope so that obtain required length overall filament length degree, distribution of lengths and good system's operability.And then the fracture zone is that a consolidation zone is used for making discontinuous long filament in the yarn fixed and make them mix globality with the maintenance yarn with any method.This flow process comprises having one or more improvement of breaking the system in district.

Characteristics of new technological flow are based on a such view, promptly importantly will arrange some " double fastener is held " long filament, and it is broken and the drawing-off flow process by whole.Double fastener hold long filament be those length enough cross over each break and two rollers of draw zone between the long filament of distance.Thereby double fastener is held long filament and provided some supportings to make the endless tow in each district have good cohesion can for other long filaments, can help maneuverability like this, particularly when counting yarn with the low dawn of few filaments manufacturing.People be sure of to need more fracture zone can reach a high overall ratio as a means of boosting productivity if adopt low speed than just causing the long long filament that can hold long filament as double fastener in the fracture zone but do like this.For filament length being reduced to a low level,, also require to have more fracture zone to meet the needs of producing yarn with multiplicity of filaments termination.The filament end of stretching out is considered to and can provides feel preferably to yarn.The applicant etc. once found have a more excellent operating process can optimize the maneuverability of machinery when with short fiber manufacturing Denier yarn per inch filament end number being optimized.In order to boost productivity, the overall ratio of this flow process must remain on high level, and the increase of speed ratio must be shared by at least two fracture zones, and it is maximum requiring to make maneuverability simultaneously, and this requires to keep the double fastener of a certain least part to hold fiber in each district.The applicant etc. once found to produce desirable product, must careful some technological parameter of control.First fracture zone 〉=2.0 speed ratio D1 and second fracture zone 〉=relation of 2.0 speed ratio D2 also should satisfy following equation preferably:

(D2-1)/(D1-1)≥0.15

Better should satisfy following equation:

(D2-1)/(D1-1) 〉=0.15 also≤2.5

In also having a preferred embodiment, the head of district in second district also is restricted to 0.4 times that is less than or equal to the first district head of district.

Also being provided with a district that separates in a further advantageous embodiment is mainly used to the long filament that drawing-off ruptured and no longer makes its fracture.

In also having some embodiment, before the fracture zone, also use drawing zone heating or drawing of fiber heatedly not, but do not make its fracture.Add thermal fiber and control product performance such as can use the annealed zone during shrinkage factor when needs in addition.The annealed zone is a modal part in the drawing zone, but can use on during the course all places.

Therefore this flow process can make far-ranging stretch break method yarn owing to offer an opportunity and can introduce various fibers with the mode that did not disclose in the past.For example, in this flow process, adopt multiple different section and the fiber that adds in different position introducings just can obtain uncommon and novel effect.The typical practice of this product is to mix with continuous filament yarns and discontinuous filament yarn to form, and the position that continuous filament yarns is introduced is in fracture and the downstream of draw zone and the upstream of consolidation zone.Use stretch break method, particularly use the operation sequence of the applicant's uniqueness, we once obtained the product that following performance had not been expected from polymeric material:

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament be avg. greater than 6 inches (~15.24 centimetres), and fiber to have a filament length distribution characteristics be 5% to have the length greater than 1.5avg. less than 15% long filament.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament is greater than 6 inches (~15.24 centimetres), and wherein fiber comprises continuous filament yarn along the mixing of length of yarn and discontinuous long filament, and continuous filament yarn has the fracture elongation less than 10%.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament is greater than 6 inches (~15.24 centimetres), and wherein fiber comprises continuous filament yarn mixing along length of yarn and discontinuous long filament, continuous filament yarn has elastic filament, its fracture elongation is greater than about 100%, and is at least 30% at the elastic recovery rate that extends after 50%.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament is greater than 6 inches (~15.24 centimetres), and the long filament and the coefficient of friction between long filament that wherein have a fiber by the discontinuous long filament of dawn number at least 1% in yarn are 0.1 or littler.Best, low friction component is a fluoropolymer.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament is that avg. is greater than 6 inches (~15.24 centimetres), and it is 5% to have the length greater than 1.5avg. to the long filament less than 15% that fiber has a filament length distribution characteristics, and wherein filament cross has width and the thick portion that has the thin portion of a plurality of quilts to couple together in width, thin portion is split in the end of discontinuous long filament, therefore thick portion is separated on the length that is at least about three double-length silk width, thereby forms the termination of splitting on long filament.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament is that avg is greater than 6 inches (~15.24 centimetres), and it is 5% to have the length greater than 1.5avg. to the long filament less than 15% that fiber has a filament length distribution characteristics, and the fiber in yarn is two kinds and can with the naked eye distinguishes its fiber of notable difference visually.Preferably this difference is the difference on the colour, the colour of fiber except brightness greater than 90% the muted color, the colored difference of two kinds of fibers is at least 2.0 CIELAB (International Commission on Illumination laboratory) unit, brightness and colored difference can be measured by the standard E-284 of ASTM (ASTM) the E12 committee, so just can be made into multicolored yarn.

A kind of yarn comprises the fixed artificial fibre of the discontinuous long filament that length is different, long filament along the length interlacing of yarn to keep the globality of yarn, wherein the average length of long filament be avg. greater than 6 inches (~15.24 centimetres), and wherein to have potential elasticity by the fiber of the discontinuous long filament of dawn number at least 1% in yarn be 30% or more long filament.Best, this fiber is the yarn of a bi-component, and wherein first component is 2GT polyester (polyethylene terephthalate), and second component is 3GT polyester (polytrimethylene terephthalate).

Once disclose different flow processs and be used for making some above-mentioned product.Also once disclosing some flow processs is used for traditional staple fibre frame is transformed into the machinery that is used for making the mechanical required feeding fiber of the formula of breaking.These flow processs comprise the management of frame operation, make it at least 500 fibers of spinning position spinning, producing multiple product simultaneously is collected in the container, these products have independent batch size from about 20 (~9.07 kilograms) to 200 pounds (~90.72 kilograms), this batch size is counted the batch of tow products less than the single big dawn; These flow processs also provide facility to make making the low dawn to be used for from least one spinning position tow being collected in the container when counting tow products.

We did various improvement to traditional technological process of breaking, and these improvement comprise:

In the fracture zone, discharge near the loose filament end of assembling the niproll and with they guide fiber cores, the distance of leaving the core center in the loose termination that this direction surrounds core is not more than discharge each associated end of clamping screw in the fracture zone and leaves the distance at core center, thereby the looping that can reduce loose termination is being discharged on the niproll.

Arranged fiber can be bent them by the path of each function section in breaking process, when the vectorial tail with path vector in first functional areas and the next functional areas of continuing puts together tail ground, can between them, form one 45 like this and spend the angle of spending, can be the floor area that this process causes a compactness like this to 180.

In the outlet of first fracture zone and when the import of second fracture zone is arranged the path of discontinuous long filament with outlet, make fiber with at first contact before nonconducting niproll contacts with the niproll of conduction, and before fiber will leave from the niproll of conduction, at first leave, when fiber moves through niproll, can reduce electrostatic accumulation like this in fiber from nonconducting niproll.

About other variations of the technological process and the product of producing, those skilled in the art work as from following explanation and can understand.

Description of drawings

From the explanation of doing below in conjunction with accompanying drawing, understand when having clearly to characteristics more of the present invention, in the accompanying drawings:

Fig. 1 is the elevation view of summary that comprises the technological process production line of first fracture zone, second fracture zone and consolidation zone.

Figure 1A is the closure of a roller group, fiber path " inferior rice eggplant " path that is at that time, and this path is to high strength fibre or to have a fiber of low-friction coefficient particularly useful.

Fig. 2 is the perspective view of the summary of being held long filament by the intrastitial filament end broken and double fastener between two roller groups.

Fig. 3 holds the graph of relation of ratio of fibers to overall ratio for double fastener, is depicted as two situations of the stretch break method fiber that uses simulation model.

Fig. 4 holds the graph of relation of ratio of fibers to speed ratio for double fastener, is depicted as the stretch break method fiber that uses simulation model under the single situation of two fracture zones.

Fig. 5 is the fracture elongation e that is conceived to fiber bFig. 4 in the sensitivity map of information.

Fig. 6 is the sensitivity map that is conceived to information among Fig. 4 of the variation that the length of fracture zone 2 compares with the length of fracture zone 1.

Fig. 7 is the sensitivity map that is conceived to information among Fig. 4 of variation of overall ratio of two fracture zones.

Fig. 8 is the elevation view of summary that comprises the production procedure line of a drawing zone, first and second fracture zones and a consolidation zone, and drawing zone also can play the effect of annealed zone at that time.

Fig. 9 is the elevation view of summary that comprises the production procedure line of a drawing zone, first and second fracture zones, a draw zone and a consolidation zone.

Figure 10 illustrates the curve among Fig. 4, and the vertical axis on the limit is expanded, and the vertical axis on the right is added, so that the curve among Fig. 4 and some actual tests data are compared.

The curve map that Figure 10 A draws for the data that the operability test that the D1 value different with D2 designed obtains is so that collect best data for the curve map of Figure 10.

Figure 11 is used for implementing Fig. 1,8 and 9 and the elevation view of the summary of the machinery of the technological process of modification.

Figure 12 is the perspective view of the vortex jet pipe that is used for making loose long filament among Figure 11 and turns round and round around fiber.

Figure 13 is the schematic illustration that is used for making the feeding fiber to saunter by the Fiber Distribution rotor and enter the device of sauntering that scalds container of shaking.

Figure 14 is the cutaway view of Figure 13 rotor.

Figure 15 is from the yarn testing of reality and the filament length distribution map that this test simulation is obtained.

Figure 16 and 17 illustrates the simulation of two comparable examples that only use single fracture zone and the Fiber Distribution that draws, and this distribution exceeds scope of the present invention.

Figure 18 and 19 is illustrated in simulation of carrying out under other operating conditions and the Fiber Distribution that draws, and this distributes within the scope of the invention.

Figure 20 illustrates the summary technological process of Fig. 9, and wherein the feeding fiber of Tian Jiaing is introduced at the upstream extremity of consolidation zone.

Figure 21 illustrates the summary technological process of Fig. 9, and wherein the upstream extremity of feeding fiber in first fracture zone of Tian Jiaing is introduced into.

Figure 22 illustrates the summary process of Fig. 9, and wherein the upstream extremity of the first interpolation feeding fiber in first fracture zone is introduced into, and second adds the feeding fiber is introduced at the upstream extremity of consolidation zone.

Figure 23 is the summary elevation view of graph among Fig. 9, wherein comprises an annealed zone after consolidation zone.

Figure 24 illustrates a microphoto with stretch break method fiber of the termination of splitting.

Figure 25 is the cross section of long filament among Figure 24.

Figure 26 is used for the perspective view of the injector of entwining of consolidation fibre.

Figure 27 is the cross section 26-26 by injector among Figure 26.

Figure 28 is used for the pneumatic twisted element of consolidation fibre, and the left side is the cutaway view that cuts along fiber path among the figure, and right-hand part is a plane.

Figure 29 is the isometric view of the staple fibre frame of prior art, and this frame can provide the tow products of big dawn number by the flow process that feeds traditional short fiber yarn.

Figure 30 is the isometric view of improved staple fibre frame, and this function provides the tow products of Denier and big dawn number.

Figure 31 is the isometric view of improved staple fibre frame, and this machine can provide the tow products of Denier from indivedual positions by the flow process of feeding stretch break method yarn.

Figure 32 is one and has the sketch map that the technological process production line of floor area can be saved in the path of turning back.

Figure 33 A, B and C are respectively the sketch map of the functional areas path vector of each section among Figure 32.

Figure 34 A and 34B are the cutaway view of a groove, and this groove was assembled loose filament end before fiber moves through niproll makes them towards fiber core.

Figure 35 is for regard to different average filament length, yarn strength to consolidation device two injector spacings from typical plot.

Though the present invention will describe in conjunction with its preferred embodiment, should know that the present invention do not exceed with this embodiment, on the contrary, the present invention should cover all that and be included in substituting, revising and being equal in intention that claim of the present invention limits and the scope.

The specific embodiment

Consult accompanying drawing, Fig. 1 illustrates and uses at least one first fracture zone 34, second fracture zone 36 and a consolidation zone 38 to break the sketch map that fiber 30 forms the more excellent process of yarn 32.The fiber 30 that can have several fibers 30a, 30b and 30c is fed in the flow process by the first roller group of being made up of roller 44,46 and 48 42 at the upstream extremity 40 of flow process.Roller 46 is driven by traditional motor/gear-box and controller (not shown) by predetermined rotating speed, and roller 44 is driven owing to contacting also with roller 46 with 48.Fiber 30 is fed in the second roller group 50, thereby forms first fracture zone 34 between roller group 42 and 50.Roller group 50 is made up of roller 52, roller 54 and roller 56.Roller 54 is pressed desired speed and is driven by traditional motor/gear-box and controller (not shown), and roller 52 is driven owing to contacting also with roller 54 with 56.There is a length L first fracture zone 34 1The position is between the jaw on the line of centres 60 of the jaw on the line of centres 58 of roller 46 and roller 48 and roller 52 and roller 54.Drive fiber with roller group 42 by the first rotating speed S1, and drive fiber by the second rotating speed S2 that is higher than rotating speed S1, so just can in first fracture zone 34, improve the speed of fiber with roller group 50.The relatively formation first speed ratio D1=S2/S1 of the fiber speed on two roller groups 42 and 50.Any slip that do not have between nip rolls and fiber, fiber speed can be identical with the nip rolls surface velocity on driven voller 46 and 54 like this.The increase of fiber speed will make intrastitial long filament be longer than the length L that is stretched in first fracture zone 34 1Until surpass the fracture elongation of fiber, at this moment will be ruptured by the long filament of two roller groups clamping.In this first district, in order to make filament breakage, speed ratio D1 should reach such degree makes the maximum strain that is applied on the long filament surpass the fracture elongation of fiber, and this is the known requirement of breaking fiber.The condition of above-mentioned broken filament is satisfied if be fed into that fiber in the process all is made of continuous filament yarn, and all long filaments will be ruptured in first fracture zone so.After continuous filament yarn is ruptured,, be that discontinuous filament fiber also can drafted dawn number with the minimizing fiber in first fracture zone 34 at present along with the continuation of fiber speed increases so that reach the rotating speed S2 of roller group 50.

Then fiber 30 is fed into the 3rd roller group 62, thereby forms second fracture zone 36 between roller group 50 and 62.Roller group 62 is made of roller 64,66 and 68.Roller 66 is driven by traditional motor/gear-box and controller (not shown) by desired speed, and roller 64 is driven owing to contacting also with roller 66 with 68.There is a length L 2 second fracture zone 36 just between the jaw on the line of centres 72 of the jaw on the line of centres 70 of roller 54 and roller 66 and roller 64 and roller 66.Drive fiber with roller group 50 by the second rotating speed S2, and drive fiber by the 3rd rotating speed S3 that is higher than rotating speed S 2, so just can in second fracture zone 36, improve the speed of fiber with roller group 62.The relatively formation second speed ratio D2=S3/S2 of the fiber speed on two roller groups 50 and 62.Any slip that do not have between nip rolls and fiber, fiber speed can be identical with the nip rolls surface velocity on driven voller 54 and 66 like this.The increase of fiber speed will make at intrastitial most of long filaments and be longer than the length L 2 that is stretched until surpass the fracture elongation of fiber in second fracture zone 36, at this moment will be ruptured by most of long filaments (double fastener is held long filament) of two roller groups clamping.In this second district, in order to make filament breakage, speed ratio D2 should reach such degree to be made and is applied to double fastener and holds the fracture elongation that maximum strain on the long filament surpasses fiber, and this is the known requirement of breaking the fiber with discontinuous long filament.Along with the continuation of fiber speed increases so that reach the speed S3 of roller group 62, discontinuous filament fiber also can be stretched in second fracture zone to reduce the dawn number of fiber.

Then fiber 30 is fed into the 4th roller group 74, thereby forms consolidation zone 38 between roller group 62 and 74.Roller group 74 is made of roller 76 and 78.Roller 76 is driven by traditional motor/gear-box and controller (not shown) by predetermined rotating speed, and roller 78 is driven owing to contacting also with roller 76.Consolidation zone 38 has 3 of length L between the jaw on the line of centres 82 of the jaw on the line of centres 80 of roller 66 and 68 and roller 76 and 78.Consolidation zone 38 comprises the interlacing nozzle of some fixed facility as illustrating between roller group 62 and 74.Because drive fiber with roller group 62 by the 3rd rotating speed S3, and drive fiber with roller group 74 by the 4th lower rotating speed S4, therefore fiber speed can slightly reduce in consolidation zone.The relatively formation speed ratio D3=S4/S3 of fiber speed on two roller groups 62 and 74.Any slip that do not have between nip rolls and fiber, fiber speed can be identical with the nip rolls surface velocity on driven voller 66 and 76 like this.Make long filament entangled to each other and link together and form short fiber yarn thereby entwine to spray, because yarn is that changing down forms in this concrete consolidation zone, the length of fiber can slightly shorten when doing like this.May increase the speed of yarn in some cases in consolidation zone 38, the continuation along with fiber speed increases up to the rotating speed S4 that reaches roller group 74 in this case, in consolidation zone 38 some drawing-off will take place.

Continue to consult Fig. 1, shown in roller group 42,50 and 62 be three roller groups, fiber be basically " as the crow flies " by the roller group, have only minimum part to be wrapped in around the nip rolls.This to this flow process normally simple effective method can provide good clamping and the simple path of introducing to fiber.It is believed that importantly and when fiber is ruptured, control the static load that accumulates on the fiber in fracture zone 34 and 36.Owing to the free-fiber termination that fibrous fracture causes can be repelled by electrostatic force and stretch out from the surface of fiber when long filament slides over each other.The free end of the static electrification that these stretch out can be wrapped on the niproll, particularly in roller group 50 and 62, thereby causes the pause of machinery.It is believed that this fiber is contacted with the nip rolls surface of conduction allows static load dissipate.This point can accomplish, if make clamping still unconsolidated discontinuous fibre niproll for example in the roller 44,48,52,56,64 and 68 at least one roller have the conductive surface of metal.Roller 76 also can have a conductive surface, but this is unimportant, because free end is consolidated with fibre core when fiber moves through this jaw.Equally, roller 44 can not need to make metal, because fiber still is a branch of continuous filament yarn in this, free end do not occur.On roller 48 owing in fracture zone 34, there is dynamic filament breakage to take place, can have some free end to occur, so roller 48 to have conductive surface may be useful.With regard to roller group 50, roller 52 and 56 has the metal surface, and this surface contacts with nonconducting, the flexible artificial rubber on the roller 54 is surperficial.It is also important that when roller group of contact as 50 the time, arrange discontinuous long filament properly in the path that enters and leave the roller group, fiber is contacted with the conduction niproll earlier, and then contact with nonconducting niproll, and when leaving, at first will leave from nonconducting niproll, and then from the conduction niproll leave, when fiber moves through niproll, can reduce electrostatic accumulation like this in fiber.In other words, entering the surface that the fiber of jaw at first contacts should be conductive surface, and the surface of leaving the last contact of fiber of jaw also should be a conductive surface.If not so, but fiber after leaving metallic roll 56 again the artificial rubber surface from roller 54 peel off, when fiber and artificial rubber are separated, will produce static load so, this electric charge can not dissipate immediately, because fiber itself is nonconducting.Therefore roller 52 and 56 be located at angledly roller 54 centers around so that fiber with roller 54 before contact with roller 52 earlier and on roller 52, forms about 5 degree or more winding angle, and disengage that back one about 5 of formation on roller 56 is spent or more winding angle at fiber and roller 54.This situation repeats on roller group 62.

Because the winding on many rollers seemingly takes place when fiber leaves between roller jaw, it is believed that and it is also important that, when leaving a flexible artificial rubber niproll, fiber, fiber is contacted with the rigidity niproll such as the metal niproll on opposite no matter it is conduction or nonconducting having the niproll of rigidity or elastic surface.Like this when fiber can be trapped in the elastic surface of artificial rubber roller, it can be peeled off along the rigid surface of relative niproll from elastic surface and do little winding at rigid surface.Can finish this purpose around the winding angle of niproll as mentioned above with metal surface.This is considered to reduce the winding on the roller.If rigid roller conducts electricity, so also can have top said additional advantage.

The another kind that Figure 1A illustrates roller group 42 is called as " inferior rice eggplant " formula winding with the mode that fiber is incorporated in the roller group.In this alternative, fiber is fed into the following of roller 44 rather than crosses its top, be wrapped in then roller 44, roller 46 around and go to roller 48 below.Can increase contacting between fiber and roller 44,46 and 48 so significantly.As fruit fiber need with good being frictionally engaged of roller group in order to avoid fiber slides when crossing the roller group, this is a useful technology.Situation about need do like this may be to need the roller group to send big disruptive force or when having low-down coefficient of friction between between the fiber long filament within it and fiber and the nip rolls surface when fiber has high strength.The confficient of static friction of fluorine-contained polymerisate fibre between its long filament is less than or equal to about 0.1 and comes to this a kind of fiber when add suitable employing the in man-hour " inferior rice eggplant " formula winding with stretch break method.Adopt the winding of this inferior rice eggplant, fiber contacts with just forwarding to the roller 48 with conductive surface after the roller 46 with non-conductive surface of elastomer contact under breaking state, thereby one of formation is greater than the 90 big winding angles of spending 55 on roller 48.Leave the static that can dissipate effectively and produce along with fiber from elastomer so as mentioned above.

With regard to whole industry speech, fiber one speech has various implications.But with regard to this illustrative purposes, fiber one speech means elongated textile material with one or more terminations or the tow of being made up of identical or different materials, this tow has many discontinuous or continuous long filaments, and, thereby between long filament, keep sizable sliding without fixed.Long filament is the unit of the one-component of continuous or discontinuous (being fixed length) material.Yarn or short fiber yarn mean the elongated textile material with the fixed long filament that comprises discontinuous long filament, and wherein consolidation fibre has sizable tensile strength and along the globality of length of yarn, and also has the long filament sliding, but restricted.Continuous filament yarn also can appear in yarn or the short fiber yarn.

The feeding fiber of above-mentioned technological process can also will illustrate below from the bobbin package or the fiber that can freely extract out in container in bulk of fiber.Consolidation fibre can reel the packing or in bulk in container so that transfer to another process or shipment; Or move on on the other mechanical organ so that further processing.

The fracture of fracture zone and long filament relates to the fiber that will have continuous or discontinuous long filament in a section to be quickened, and its main purpose is will make more than 20%, be preferably the filament breakage more than 40%.100% long filament all can be ruptured in the time will feeding in the fracture zone than the fracture head of district's continuous or discontinuous long filament.The fracture of fracture zone and long filament also can comprise cutting or weaken all or part of continuous or long and discontinuous long filament as with cutting converter apparatus or disruptor lever apparatus (as authorizing the U.S.2 of New, 721,440 or authorize the U.S.4 of Lauterbach, illustrated in 547,933).It is mixed and disorderly that these devices can reduce some of filament breakage position in the disruptive force that is applied on the niproll and the controlling fiber.

First fracture zone and second fracture zone mean two well-separated fracture zones, fiber by the flow process of two fracture zones in second fracture zone be after first fracture zone, but first fracture zone and first fracture zone first district in the flow process not necessarily and then not necessarily, second fracture zone.The feeding fiber that enters first fracture zone can be continuous filament fiber, contain discontinuous fibre that long long filament will rupture in first fracture zone or continuous and combination discontinuous filament fiber.Fixed meaning links together intrastitial long filament, and available any fixed facility is as single gas nozzle, a plurality of gas nozzle, real twisting apparatus, twisting apparatus, adhesive applicator or analog, the winding device etc. of alternating layer.

During the actual crack fiber, people know that the speed ratio along with broken fiber increases in single fracture zone, and the required pulling force of broken fiber can reduce.Less than two extremely low speed ratio the time, pulling force increases sharply, and it is believed that this pulling force can make consolidated fibers, thereby makes the friction between adjacent filament increase, cause the difficult fracture of single Zhi Changsi.As a result, pulling force is very high and unstable, causes operability generation problem, is that whole fibrous fracture rather than spuious list prop up filament breakage when consequently rupturing.Reason for this reason, need with 2.0 or bigger speed ratio operate each fracture zone.This also can help improving the output efficiency of product.In fixed yarn, also need a large amount of filament end, this point can be accomplished, as long as the length of second fracture zone is reduced to than the quite short length that shortens long filament in the fiber in first fracture zone, thereby in the fixed fiber of per inch, causes more filament end to get final product.More excellent way is to make the length L 2 of second fracture zone be less than or equal to 0.6 times of the first section length L1.More excellent way is to make L2 be less than or equal to 0.4 times of L1.It is that nearly all fiber filament from first district can both be ruptured that the minimum length in second district is had a limit, but this is undesirable, because it can make pulling force increase very highly, people know that disruptive force can increase along with the minimizing of section length.The actual lower limit of the length of fracture zone 2 is L2 〉=0.2L1.Inference is preferably done first fracture zone to such an extent that have sizable length than second fracture zone thus because known in long section the required pulling force of broken filament can reduce.People be sure of the average filament length (as being set up by second fracture zone) to any given production, and importantly L1 wants long enough to be presented under the disruptive force as a means of the filament length than growing that reduces required disruptive force and will expose more long filament weakness.It is believed that average filament length is more preferably greater than 6.0 inches, experience according to two fracture zones, it is big or 12.0 inches to this means that L2 is roughly the twice of average filament length, and is 0.6 o'clock at the ratio of the required L2/L1 of maximum, and L1 is greater than 1.67 * 12.0 or 20.0 inches.

Exist certain relation between first and second fracture zones, this relation can guarantee that process has good operability, and yarn has some required characteristic and comprises filament length and distribution, and the filament end that increases can be provided in the stretch break method yarn.Good operability return greater than the 200-250 sign indicating number/minute, particularly provide possibility greater than the reliable high speed operation under about 500 yards/minute output speed.In order to understand the relation between first and second fracture zones preferably, discuss the definition that double fastener is held long filament in conjunction with Fig. 2 earlier now.Fig. 2 illustrate that the fiber that only has continuous filament yarn is walked about on direction 81 and by a fracture zone 34a as first fracture zone 34 in Fig. 1.Fracture zone 34a extends across a segment length L1a between two roller group 42a and 50a.Roller group 42a is driven by first rate S1a, and roller group 50a is driven by the second speed S2a that is higher than speed S1a, thereby constitutes speed ratio D1a=S2a/S1a.The speed of fiber 30 just is increased in the fracture zone like this, so all will be ruptured in length L 1a at the continuous filament yarn that upstream extremity 85 is fed.Though the position of upstream extremity shown on the figure 85 is just in time in the back of roller group 42a, upstream extremity 85 indication positions can be just in time in the front of roller group 42a, back or in jaw.In whole argumentation, the upstream refers to the direction that fiber is come in, and the downstream refers to the direction that fiber is gone out.Fiber has a fracture elongation, represents with percentage, and the long filament of representing fiber is at the direction that the applies load extension percentage before filament breakage just in time.The representative value of fracture elongation was about 300%, and is about 10% after the enhancing that is stretched concerning the artificial fibre such as polyester of spinning before the increase that is stretched.At any time, constantly, there are some long filaments to be ruptured as shown in Figure 2, though also there are some long filaments to be stretched also not fracture as long filament 90 and 92 as long filament 84,86 and 88.Long filament 84 is called as the not controlled long filament that swims because its upstream extremity 84a or downstream 84b both not by roller group 42a also not by 50a clamping of roller group and control.Long filament 86 is called as the not controlled long filament of single clamping and has not controlled termination, a downstream, because it has only by a roller group 42a clamping and control, downstream 86a is not by any roller group 42a or 50a clamping and control.If termination 86a from the center of fiber 30 protruding some apart from d as shown in the figure, this termination 86a will be wrapped on the roller in the roller group rather than advance by this process on direction 81 like this, thereby will go wrong on roller group 42a or 50a.Long filament 88 is called as single clamping control long filament, and it is by a roller group 50a clamping and control, and upstream extremity 88a is arranged not by any roller group 42a or 50a clamping.Termination 88a is than the less problem of termination 86a, because the former is pulled that the latter is pushed through process by process.Termination 88a is not easy to separate as termination 86a from the center of fiber.Long filament 90 and 92 is called as double fastener and holds the supporting fiber, because they are by two roller group 42a and 50a clamping and control in the diagram moment.Their effect can remain on other not controlled long filament on the position in fibrillar center district as " scaffold ".With other is that the long filament of single clamping is different, and they are subjected to sizable pulling force, so their can remain on the center tightly with other long filament and limit the termination such as the stretching out of 86a.At next constantly, long filament 90 and 92 can be ruptured, but at this constantly, other long filament such as long filament 86, its termination 86a may be become double fastener by the 50a clamping of roller group and hold.People be sure of importantly should to have at any time the double fastener of at least one minimal amount to hold long filament to exist, and so just can keep the scaffold of long filament and the assurance process is moved well.Equaling double fastener at the long filament sum of upstream extremity 85 holds the number of long filament and adds that not controlled long filament comprises the long filament that swims and the number of single clamping long filament.

The process of setting up model is used to predict that under various process conditions double fastener holds the number of long filament.Analytical expression is to use for single break district and continuous feeding long filament.The long filament that during simulation the process first identical principle of employing in multibreak split plot is fed into each district in the process of multibreak split plot can be continuous or discontinuous.The result in single break district can be consistent mutually well.The analytical expression of the supporting index in the single break district can be derived from first principle, and first principle is used following supposition:

The input fiber is continuous

It is constant that quality in the district keeps

Speed at the upstream and downstream border fiber of distinguishing is prescribed

Long filament is mutual to rupture irrelevantly

Long filament ruptures along the length of section equably

" supporting index " expression formula that derives is:

SI=-Ln (((D/ (1+e b))-1)/(D-1))/(D* (1-(0.5/ (1+e b)))) number of controlled fiber of the number of SI=supporting fiber/not wherein

L n=natural logrithm

Velocity ratio in D=degree of draft=district

e bThe fracture elongation of=fiber; 10% usefulness 0.1 is represented

Once researched and developed a kind of Monte Carlo Calculation machine analogy method and analyzed a technological process with multi-region fracture and drawing-off.Tracer fiber is by the motion of flow process during simulation, and fiber speed applies (as an example) in each district by the niproll group.The kinematics that applies determines that single clamping and double fastener hold the motion of long filament.Randomness has when double fastener is held filament breakage.According to the argumentation " mechanics of stretch break method " (Textile Research Journal is rolled up July in 1972 42 No. 7) of Ismail Dogu, when fracture elongation was arrived in the strain accumulation of long filament, it just ruptured randomly along section length.The fracture of long filament and intrastitial other long filaments are irrelevant.The long filament that swims is discussed in many ways, the speed of taking the upstream rollers group from " desirable drawing-off " long filament up to its guide hold arrive the downstream rollers group till to optional situation, the speed of long filament depends on the speed of adjacent filament in this case.Analog result with the supporting exponential sum technology tension force of single break district analytical Prediction, and all consistent well with the actual technology tension force of measuring.Simulation model is at U.S. MA 1760, the Matlab of the Mathworks company of Natick 5.2 move on the computer,, on this has the loom of Intel Pentium II 450MHz processor, need only change reasonable time and just can obtain a result for 1000 long filaments.Also gear to actual circumstances with 3000 long filaments of this system handles.Simulation to the fracture fiber length distribution that flow process is done in two districts also coincide well with the actual distribution that records.

Continue to consult Fig. 2, when the examination double fastener is held the number of long filament effective way be with number as percentage, come like this to hold the long filament and the number of controlled long filament not at the upstream extremity 85 comparison double fasteners of the upstream extremity of section length such as length L 1a.By the definition, the number that double fastener is held long filament is all identical with downstream 93 at the upstream extremity 85 of section L1a, but not the number of controlled long filament always the upstream extremity at section length L1a is more than downstream.Because the cause of speed ratio D1a, the fiber of discontinuous long filament is drafted, and is therefore always less at the dawn of downstream fiber number in the downstream of L1a.Holding long filament for the double fastener of similar number always has more not controlled long filament to need to be supported at upstream extremity.

Consult Fig. 3 now, the result of modeling Simulation under two kinds of situations shown in it, a kind of situation is to use a fracture zone to finish overall ratio, and another kind of situation is to use two fracture zones to finish identical overall ratio.The overall ratio of known multi-region section can be multiplied each other by each speed ratio of each section and get (Dt=D1 * D2) or directly calculate and get (Dt=S3/S1).On the Vertical surveyors' staff of Fig. 3, be depicted as double fastener and hold the number N of supporting long filament DgTo not controlled long filament sum N UcRatio, this ratio is the upstream extremity in the single break district, or the upstream extremity in second fracture zone of double break split plot (promptly supposition is to be made of two districts, and this will be N Dg/ N UcMinimum) calculate.Other of two districts is assumed to:

L2=0.33L1

D1=D2

D1≥2.0;D2≥2.0

The fracture elongation e of fiber in two fracture zones b=0.121

Curve among the figure is overall ratio is held the ratio of long filament and not controlled long filament number to double fastener a relation.Single district's situation with dashed lines 94 and diamond data points illustrate, and the two-region situation illustrates with solid line 96 and square data point.As shown in the figure, under the identical condition of overall ratio, the two-region situation always double fastener is held long filament and not controlled long filament provides a higher ratio, it is believed that the operability of such flow process will be higher.

Can see that from the single break district of Fig. 3 when speed ratio increased, the number that double fastener is held long filament can reduce, and when speed ratio reduced, the number that double fastener is held long filament can increase.To the double break split plot, people can see in order to reach given overall ratio will run into a problem with this relational application.If increase the number that double fastener in first district is held long filament, can reduce the speed ratio in first district so, but the essential like this speed ratio that increases in second district can be kept identical overall ratio, and this can reduce the number that double fastener in second district is held long filament, and this is again undesirable.This problematic relation will be with the figure explanation in Fig. 4.

Fig. 4 illustrates N along vertical axis Dg/ N UcAs Fig. 3, but be two relations between the speed ratio of fracture zone along horizontal axis.If because the speed ratio 1 of a section, the meaning is exactly that the speed of " advancing " equals the speed of " going out ", will filament breakage can not take place, so should respectively deduct 1 from the speed ratio D1 of first fracture zone and the speed ratio of second fracture zone when the speed ratio of two fracture zones relatively.When second speed ratio equals 1, relational expression (D2-1)/(D1-1) will equal zero in this case, and the value that this curve and vertical axis intersect will be pointed out the N in single break district Dg/ N UcValue.For example as Dt=25 and D2=1, the value on vertical axis will be about 0.01, and the value of single break district curve when Dt=25 is identical among this value and Fig. 3.To being assumed to that the curve of two sections among Fig. 4 is done:

Dt=25

D1>=2.0;D2>=2.0

L2=0.33L1

e b=0.1

Because second district's speed ratio is on molecule, the curve 100 in second district has the shape of curve among Fig. 3.Because first district's speed ratio is on denominator, therefore the curve 98 in first district has the shape of curve reversing among Fig. 3.Move along horizontal axis and can see that minimum occurs in two N Dg/ N UcIn the section in the section (this value is determined the limit of operability), promptly the section by heavy line 102 representatives comprises a part 104 first fracture zone curves 98 and a part 106 second fracture zone curves 100, and both approximate 0.7 with (D2-1)/(D1-1) value is the boundary.If be N Dg/ N UcSet a suitable minimum level and be 0.02 or 2% as horizontal line 108, under the diagram condition, value (D2-1)/(D1-1) should maintain between about 0.2 (intersection point of dotted line 110 and horizontal axis) and 2.0 (intersection points of dotted line 112 and horizontal axis) so.Optimum condition is about 0.7 (intersection point of dotted line 114 and horizontal axis), the N of two sections at that time Dg/ N UcValue all is about 0.04 or 4%.When being lower than the optimal value 0.7 of (D2-1)/(D1-1), N Dg/ N UcValue descends fast, and does not descend being higher than at 0.7 o'clock so soon.And value (D2-1)/(D1-1) is about more than 5.0, N Dg/ N UcValue is based on evening up.Therefore use the process of breaking of two fracture zones to have good operability in order to guarantee, the upper limit (D2-1)/(D1-1) is important not as good as lower limit.

The simulation process of setting up model is except the situation that is used for two fracture zones, and the sensitivity of optimal value that also can be used to explore (D2-1)/(D1-1) is the good acceptable N of operability so that make number that double fastener holds long filament for maximum thereby draw one Dg/ N UcValue.Fig. 5 illustrates the sensitivity to fibrous fracture percentage elongation parameter.Three curves similar to curve among Fig. 4 that draw among the figure, wherein every curve is represented fibrous fracture percentage elongation e bA different value.e b=0.1 o'clock curve and the curve among Fig. 4 are identical.Being assumed to of these three curves:

Dt=25

D1>=2.0;D2>=2.0

L2=0.33L1

Can see along with e bBe increased to 0.15 from 0.05, the number that double fastener is held fiber increases, but that optimal value (D2-1)/(D1-1) rests on is about 0.7 constant, extends through each intersection point and horizontal axis to segment curve at this place's dotted line 116.If someone wishes to improve the operability of two given fracture zone processes, he can be except e bKeep all procedure parameter constant and add some fibers and improve operability in addition with higher fracture elongation.But can change the performance of yarn product like this.

Fig. 6 illustrates the sensitivity of section length than parameter.Draw among the figure with Fig. 4 in three similar different curves of curve, wherein each bar curve is represented the different value of the ratio of 2 couples of L1 of fracture zone length L, and just identical with curve among Fig. 4 when L2=0.33L1.The supposition of these three curves is:

Dt=25

D1≥2.0;D2≥2.0

e b=0.1

For section 1, three curves are all identical overlaps for all.Can see that working as L2 reduces to 0.25L1 from 0.5L1, double fastener is held the number (N of fiber Dg/ N UcRatio) just slightly increase, the optimal value of (D2-1)/(D1-1) just changes to about 0.8 from about 0.5 simultaneously.This change on (D2-1)/(D1-1) can be when dotted line 118 extends through L2=0.5L1 distance between these two dotted lines of the intersection point of the intersection point of a pair of segment curve and horizontal axis and dotted line 120 a pair of segment curve when extending through L2=0.25L1 and horizontal axis see.Therefore it seems in the flow process of two fracture zones, as long as the ratio between change L2 and the L1 reduces to the operability that 0.25L1 just can improve process slightly with L2 from 0.5L1.

Fig. 7 illustrates the sensitivity to the overall ratio parameter, draw among the figure three with Fig. 4 in the similar different curves of curve, each bar curve is represented the different value of an overall ratio Dt.Represent curve and the curve among Fig. 4 of Dt=25 identical.Being assumed to of these three curves:

e b=0.1

D1≥2.0;D2≥2.0

L2=0.33L1

Can see that Dt reduces at 4 o'clock from 50, the number that double fastener is held fiber increases, but that optimal value (D2-1)/(D1-1) still rests on is about 0.7 constant, and dotted line 122 extends through each intersection point and horizontal axis to segment curve at that time.If someone wishes to improve the operability of given double break split plot flow process, he can keep all technological process parameter constants except Dt, just reduces Dt and improves operability.But because flow process productivity ratio height depends on Dt, such change may make technological process uneconomical.

Fig. 8 is the elevation view of summary of another embodiment of stretch break method flow production line, and this embodiment adds a drawing zone 124 on the embodiment in the Fig. 1 with one first fracture zone 34, second fracture zone 36 and a consolidation zone 38.This drawing zone also can play the effect of annealed zone.Fiber 30 can have several fiber 30a, 30b and 30c as shown in Figure 1, and they are fed in this flow process by a zero roller group 128 that is made of roller 130,132 and 134 at the upstream extremity 126 of this flow process.Roller 132 is pressed set rate by traditional motor/gear-box and controller (not shown), and roller 130 is driven owing to contacting also with roller 132 with 132.So fiber 30 is fed in the first roller group 42, thereby forms drawing zone between roller group 128 and 42.Drawing zone 124 has a length position between the jaw on the center line 138 of jaw on the center line 136 of roller 132 and roller 134 and roller 44 ability rollers 46.Press feeding speed S with roller group 128 fDrive fiber, and with roller group 42 by being higher than speed S fFirst rate S 1Drive fiber, just can make fiber speedup in drawing zone 124.With the fiber speed ratio on two roller groups 128 and 42, just can draw stretching speed ratio D 4=S 1/ S fAny slip that do not have between nip rolls and fiber, the fiber speed on driven voller 132 should be identical with the nip rolls surface velocity like this, also should be like this on driven voller 46.

In drawing zone 124, can be provided with fiber heater 140, this heater can have various ways, here have a curved surfaces shown in, this surface contacts on a segment length with fiber, and this contact length can easily be changed as long as the change fiber is attached to the arc length on the surface 142.For long heat time heating time, arc length and contact length are a little with the president under given fiber speed of upstream extremity and given stretching speed ratio.In case fiber is subjected to pulling force in drawing zone 124, the stretching of fiber will take place, and therefore for some polymer, when fiber just in time left the jaw of upstream rollers such as roller 132 and 134, the stretching of fiber or prolongation will take place.For some polymer, stretching occurs on the length of extremely lacking as less than 1 inch.In this case, heater be used for the fiber annealing that will stretch rather than with its heating so that stretch.For the fiber of this pattern, need heating if stretch, can be with roller 132 and 134 heating.Other polymer contact to the surface with heater 140 possibly and just can stretch when being subjected to some heat.The length of drawing zone is also non-key, and its size mainly should be able to adapt to heater.When operating drawing zone in some cases, fiber can not heat and is stretched (heater can be switched off and back thorough and fiber disengage) and in other cases, fiber will be heated in drawing process as shown.In some cases, fiber can have one and equal to be about one stretching speed ratio, and fiber can only be heated and do not extend.In this case, drawing zone can play the effect of annealed zone.

Drawing zone and drawing of fiber relate to the continuous filament fibers that stretches in some way makes there is not a filament breakage basically; Long filament keeps continuously.Adding thermal fiber can maybe can be not included in the stretching.Annealed zone and fiber annealing is related to the continuous or discontinuous filament fiber of heating limit fibre length simultaneously and make its not obviously elongation, and at D4 slightly less than also comprising the fiber feeding of excess slightly at 1.0 o'clock.

Use the process of Fig. 8 to can be made into new product, its method is combined them before the fracture at least two kinds of different fibers are fed in the flow process and in the fracture zone.The difference of fiber is the difference of every filament denier (dpf), for example wherein every filament denier of every of a kind of fiber filament denier another kind of fiber less than 0.9 greater than 1.5.These two kinds of fibers together move through fracture zone and consolidation zone then.These two kinds of different fibers can be combined into the feeding yarn or will have the single fibre bundle spinning of two kinds of different dpf, or just two kinds of different fibers of each tool difference dpf are put together.At drawing zone, the fracture elongation of these two kinds of fibers should be similar to.If this point becomes problem, can it and another kind of fiber be adapted a kind of pars fibrosa predraft wherein, or two kinds of whole predrafts of fiber are fed then by drawing zone not stretch.The advantage of this new product is that the rigidity of organizing of yarn can be determined and compliance can be by the fiber control with less dpf by the fiber with big dpf.Some problem that so just can overcome little dpf yarn is as having excellent handle but too weak when making fabric.

Fig. 9 is the elevation view of the summary of another embodiment of stretch break method process production line.This embodiment has added a draw zone 144 outside a drawing zone that the embodiment of Fig. 8 has 124, one first fracture zone 34, second fracture zone 36 and a consolidation zone 38.Draw zone 144 is added between second fracture zone 36 and the consolidation zone 38.As Fig. 8, fiber 30 leaves second fracture zone 36 and is fed into draw zone after roller group 62, is fed into the roller group 150 that is made of roller 150 and 152 then, thereby forms draw zone 144 between roller group 62 and 148.Roller 152 is pressed set rate and is driven by traditional motor/gear-box and controller (not shown), and roller 150 is driven owing to contacting also with roller 152.Draw zone 144 has 5 of length L between the jaw of the jaw on the center line 80 of roller 62 and roller 68 and roller 150 and 152.Drive fiber with roller group 62 by speed S3, and drive this fiber by the 5th speed S5 that is higher than speed S3, just can make fiber speedup in draw zone 144 with roller group 148.Relatively the fiber speed on two roller groups 62 and 148 just can draw drawing-off speed ratio D5=S5/S3.Any slip owing to do not have between nip rolls and fiber, therefore on driven voller 66, fiber speed is identical with the nip rolls surface velocity, also is like this on driven voller 152.Length L S should be identical substantially with the length of contiguous fracture zone, upstream, and is in this example, promptly identical with the second fracture zone length L 2 among the figure.Under this condition, the discontinuous long filament of the fiber that is come from second fracture zone thereby few fiber can rupture in draw zone can slip over the dawn number that reduces fiber in succession, and its amount is directly proportional with used degree of draft D5.In some cases, the long filament of quantity control can be ruptured, thereby makes more uniform yarn, and its mode is as people such as Scheerer said long filament of draw staple equably in PCT application WO 98/48088.This system also illustrated in the catalogue CAT.22P43297-1-4 (NS) that is entitled as " Muratec802 HR MJS, Murata jet spinning machine " that Murata Mechanology Inc. publishes.

Draw zone and drawing of fiber related in a district speed that improves fiber, its main purpose be for reducing the dawn number of discontinuous filament fiber, makes the length that keeps them more than 80% fiber, promptly have only 20% or fiber still less ruptured.Can be located on all places of consolidation zone upstream according to the intention draw zone, for example it can be located between first fracture zone and second fracture zone.

One is operated with approaching flow process shown in Figure 8, and data are collected to determine the gauge of good operability, and these data are drawn in Figure 10.Figure 10 illustrates the curve among Fig. 4, and the vertical axis on the right is added so that the flow process situation of some actual motion that draws is found out the gauge of good operability thereby the vertical axis on the left side is expanded.The situation that marks good operability is that process can be started and moved at least 5 minutes, and making can received stretch break method fiber, and input rate is 1 yard/minute (being limited in about 150 yards/minute owing to the reason of machinery from the speed of second fracture zone output).Mark bad operability be the long filament of fiber be wrapped in any niproll in the flow process around.Fixed work step is omitted to simplify flow process because this work step does not obviously influence the performability problem.Fiber is drawn out of from this flow process afterwards and is drawn rifle by waste material and draw in roller group 62 (Fig. 8).Leave in the first fracture zone L1 that the about 6 inches locational pulling force of upstream extremity slightly contacts with fiber with one and the guide wheel that is linked on the load cell is measured.The pulling force signal is monitored with regard to its changeability and peak value when low speed moves than quilt.Appear as the big pulling force peak value of correct tension signal twice and show that this is the bad operability and the operation of pulsation no matter whether flow process paused when taking place in 5 minutes more than twice/minute frequency.In all tests, keep constant parameter to be:

e b=2.38 feeding fibers

e b=0.12 for the fracture zone

L2=0.33L1

L1=48 " (~121.92 centimetres); L2=16 " (~40.64 centimetres)

L4=66.25 " (~168.28 centimetres)

Stretching speed ratio D4=2.43

Drawing zone length L 4=112

Draft temperature=188 ℃ are 12 " contact surface on

Infed material is three polyester fibers that are made of 7320 dawn continuous filament yarns, and each bar fiber is all extracted out from the packing of reeling.

Change D1 and D2 to obtain maximum overall ratio Dt, can earlier D1 be set in a value and change D2 until flow process can not be moved.Last operability is not destroyed and the point that can move is exactly the point with good operability that draws among Figure 10 so, and they are maximum Dt and function (D2-1)/(D1-1).Figure 10 A illustrates the data of collecting.The data point that adds circle among Figure 10 A is exactly those points that draw in Figure 10.The next door that adds the data point of circle at each is the Dt value, and is the value of (D2-1)/(D1-1) in parantheses.Adding of all maximum overall ratios punctuated all between Dt=20X and two curves of Dt=50x.Curve for the optimum operating point of (D2-1)/(D1-1)=0.7 of various overall ratios also illustrates with 155; Can find out the maximum overall ratio with good operability along this line is 42.8 times, is 157 points on figure.For different materials and different section length, these data will be different.The coating of using on fiber also is a condition of operability.Too much coating can have influence on the sliding and the fracture in breaking the district of independent long filament nocuously and whole fibrous fractures can take place; Very few coating and static can become problem and can increase the winding of niproll.Coating less than about 0.1% is better and better less than about 0.04%.It is the mixture of following ingredients that typical coating contains 0.04% paint: the ethylene oxide condensate of aliphatic acid, ethyoxyl, the propoxyl group alcohol, the sylvite of phosphate and the amine salt of phosphate that cover with n-nonanoic acid.Some polymer such as aromatic polyamides and fluoropolymer do not need any coating.' 778 patent of authorizing Adams's that other are applicable to that the coating of stretch break method fiber can say in front and authorize the Japanese patent gazette 58[1983 of Hirose etc.] find in-44787.

Consult Figure 10 once more, the straight line 158 at linking number strong point can compare test data and the simulation curve 98 of taking from Fig. 4 and 100 us, can see that actual operability data (test) also follow the pointed general trend of simulation, and optimum operating point (D2-1)/(D1-1)=about 0.7 also with dotted line 114 limited identical.

The equipment of flow process of application drawing 1,8 and 9 of being used for is shown in Figure 11.Feed to give fiber 30 by one of fiber in bulk several containers 160 are supplied with or by one or several bobbin packages 162 hello give.Fiber 30 moves through several disruptor guide wheels 164, and this guide wheel can be used for a plurality of terminations with fiber and condense together and make Fiber Distribution on flat being with.So fiber is crossed a deflector roll 166 and come a roller group 128a who is made of 168,170,172 and 174 and niprolls 175 of four rollers, niproll 175 is used to when introducing fiber yarn is clamped in securely the upstream extremity of drawing zone 124.All roller 168-174 are driven by traditional motor/gear-box and controller (not shown), and niproll 175 is driven owing to contacting also with roller 168.The downstream of drawing zone 124 is limited by the roller group 42a that end niproll 184 at the beginning of 176,178,180 and 182 and one on four rollers constitutes by another.All roller 176-182 are driven by traditional motor/gear-box and controller (not shown).Also be driven when contacting with roller 182 by end niproll 184, it is used to make fiber to begin by this flow process, retreats then with roller 182 to disengage.Be provided with an electric heater with curved surfaces 142 between roller group 128a and 42a, it has variable and contact length yarn, and Fig. 8 once discussed as combining.There is an electric power source (not shown) to be connected on the heater.

Be first fracture zone 34 after roller group 42a, be provided with and the identical roller group 50a of roller group 50 in Fig. 1 and 8 in its downstream.In first fracture zone, there is an electrostatic charge neutralization bar 186 to be located at the vicinity that is stretched and breaks fiber 30; Also have a vortex jet pipe 188, fiber moves through this pipe.The electrostatic charge neutralization bar is charged by an electric power source, and its pattern is the model ME100 that Simco Gong sells.Point source Xelminator device feeder apparatus 187 can be used on the position of averager bar 186 or add thereon so that control static, particularly near the roller group.When intrastitial long filament in fracture zone 34, rupture and drawing-off they rub mutually and cause disagreeable electrostatic charge when becoming the less fiber of dawn number, can the termination of long filament be pushed open from the center of fiber.Problem can be brought in the loose and termination that stretch out of this fiber when fibrous fracture is held, loose long filament can be wrapped on one of them downstream rollers.As mentioned above, a method that overcomes this problem is suitably to use the metal surface on some niproll.Another method be in the fracture zone and discharge niproll contiguously assemble loose filament end and the core of their guide fibers made the loose end around core is limited in leaving in the distance at core center on side direction, this distance is not more than from the fracture zone and discharges the distance of each relevant termination of niproll to the core center, discharges on the niproll as a means of reducing being wrapped in of loose termination.Importantly this control method will be applied on first fracture zone, the length of loose long filament may not be supported than length and on long length there.Being applied to also is useful on second fracture zone, and loose fibres still exists there.Vortex jet pipe 188 is approach finishing this method.

Consult Figure 12 now, the jet that vortex jet pipe 188 is introduced one gas leniently turns round and round loose long filament around the fibrillar center district or the fiber core of flat belt-like tissue.The vortex jet pipe is shown specifically in Figure 12.Vortex jet pipe 188 has a body 192, has a upstream extremity 194, a downstream 196 and a cylinder-shaped hole 198 to extend through the length of body 192 on it.Fiber 30 moves through hole 198 and goes to roller group 50a (seeing Figure 11) on its path.There is a gas channel 200 to extend through body and is communicated with hole 198 at the upstream extremity 194 of body.Gas channel intersects like this with the hole makes air-flow introduce and form an angle towards body downstream 196 to the hole with the direction of approximate tangent line.So just in hole 198, produce one counterclockwise to the air-flow (196 watch in the termination) of vortex, on figure, usually point out with helical flow path 202.This air-flow tends to the loose long filament winding of will stretch out from the fibrillar center district, thus the loose termination that can eliminate the length that may be wrapped on the downstream.The long filament of winding by loosely accumulate in fiber core around.For convenience's sake, being provided with a lead-ingroove 204 along the length in hole 198 on body 192 can easily be incorporated in the hole of vortex jet pipe fiber 30.

Another is finished that this method promptly accumulates in the fracture zone and discharges near the loose filament end the niproll and the approach of their guide fiber cores is to use shown in a groove and Figure 34 A and the 34B.This groove 450 has a termination 452 that is shaped, and turns up the soil near a niproll group as the roller group 50a (Figure 11) in 34 terminations, first fracture zone at interval.This groove has a vertical cavity 454, and its big I is contained in the fiber 30 in this district and has a width 456 can accumulate in loose long filament 458 and 460 and limit them and reach outside the termination of niproll in the roller group on fiber core 462 both sides.Pocket surfaces towards fiber is a conductive surface.Niproll 54a has termination 462 and 464, and niproll 52a has termination 466 and 468.Point out at 470 places at the center of fiber core, and this groove is with loose long filament guide fiber core 462, therefore loose termination is limited in leaving in the distance in core center as reach core termination 458 on every side to side, and this distance is not more than the distance 474 that the core center is left the distance 472 of the termination 468 of discharging niproll 52a and left the termination 464 of discharging niproll 54a; In this case, less distance 472 is controlled.Equally, loose termination as reach to side termination 460 around the core be limited in leaving in the distance in center, this distance is not more than the distance 478 that the core center is left the distance 476 of the termination 466 of discharging niproll 52a and left the termination 462 of discharge niproll 54a; In this case, less distance 476 is controlled.

This groove 450 can be only near the niproll of discharging and extend one section short distance from this section, perhaps it can extend on the whole length that is close to section 34 so that keep control to loose long filament in whole section.This groove 450 can randomly be provided with a lid 480 so that be completely contained in loose long filament on all directions.But the most important thing is that this groove must comprise long filament in side direction and make them can not reach the termination of niproll, they are wrapped on the niproll easily there.If be provided with lid, should have the inlet port of air ionizing device.

Consulting Figure 11 once more, is second fracture zone 36 after roller group 50a, is provided with the roller group 62a identical with 8 central roll groups 62 with Fig. 1 in its downstream.In second fracture zone 36, there is an electrostatic charge neutralization bar 20b contiguous with the fiber 30 that is stretched and breaks; Allow fiber 30 from wherein passing through with a vortex jet pipe 208, situation is similar to first fracture zone of discussing just now.In second fracture zone, after roller group 50a, have one to inhale silk device jet pipe 212 near its upstream extremity.Inhaling a silk device jet pipe provides the air-flow of general gentleness to be used for catching the loose filament end of coming out from roller group 50a at fiber 30 direct of travels they can be wrapped on the roller group 50a.Inhaling silk device jet pipe 212 is ITD110 types that Airvac Gong sells.A this suction silk device also can be used in first fracture zone after the roller group 42a, has some discontinuous long filaments if enter the fiber in this district.

After roller group 62a, be draw zone 144, be provided with the roller group 148a identical with Fig. 9 central roll group 148 in its downstream.In draw zone 144, have one to inhale silk device jet pipe 214, a plurality of buffer roll 216 and a plurality of guiding roller 218.Buffer roll provides some resistances to make fiber have dawn number uniformly to the drawing-off of long filament.Near roller group 148a upstream, a vortex jet pipe is set such as vortex jet pipe 208 also comes in handy.

After roller group 148a, be consolidation zone 38, be provided with and Fig. 1, roller group 74a that 8 and 9 central roll groups 74 are identical in its downstream.In consolidation zone 38, have one to inhale a silk device the jet pipe 220 and injector 83a that entwines.During practical operation, the injector 83a that entwines often is placed on the distance of leaving roller group 148a in the consolidation zone and is about 1/3 to 1/2 of consolidation zone length.Figure 26 is the perspective view of injector 83a of entwining, and Figure 27 is its cutaway view, has a fiber of breaking 30 entering fiber channel 320.Fiber channel 320 is looked from upstream end 322, and cross section preferably becomes round and mellow triangle.Injector 83a is provided with first cell wall 324 entering on the guide face 326, this wall provides wall attachment effect together with import outer surface 328 at upstream end 322; And on the guide face 330 of leaving away, being provided with second cell wall 329 (Figure 27), this wall provides wall attachment effect together with outlet outer surface 332 at the end 334 of leaving away of fiber channel 320.There are a tension groove 336 and fiber channel 320 to intersect.Consult Figure 27, have a gas admission passage 338 that gas is supplied with fiber channel 320 and make the fixed yarn that becomes of fiber entanglement.Gas passage 338 is positioned at angle 340 and leaves away the downstream of end 334 and the direction of advancing at fiber by injector towards injector, discharges from the upstream extremity of fiber channel thereby can reduce gas.In addition, entwine that the yarn path of injector is positioned to and roller group 148a and 74a (Figure 11) between fiber path 344 342 make and be not discharged into the outer flow direction of yarn path upstream extremity and leave fiber path downwards at angle.Deflector roll 346 and 348 can be used to help the guiding fiber to pass through injector.Handle like this to enter at fiber and can reduce scattering of any loose long filament in the fiber when entwining injector from the gas of yarn path upstream extremity discharging.This injector 83a that entwines has more detailed explanation authorizing in the United States Patent (USP) 6,052,878 of Allred etc., this patent by this paper with reference to quoting.The interconnected injector of other long filaments also can be used for present embodiment.One of them such injector the injection frame catalogue of Murata and above the WO patent application gazette mentioned; Explanation was once arranged in 088.Another interconnected injector has explanation authorizing in the U.S. Pat 4,825,633 of Artz etc., this patent by this paper with reference to quoting.Fiber 30 just becomes the fixed yarn 32 (Figure 11) with good cohesion and intensity after moving through consolidation device (as in the injector of discussing just now, or other facilities that disclose in front).

The injector of Artz is described in conjunction with Figure 28 now, and the left side is the cutaway view that cuts along fiber path in the figure, and right-hand part is a plane.At United States Patent (USP) 4,825, in 633, this injector is called as pneumatic twisting element, can be by United States Patent (USP) 5,048, and 281 mode is controlled.Pneumatic twisting element 83b comprises jet member or first nozzle 350 and a twisting member or second nozzle 352 with spinneret orifice 353 with spinneret orifice 351.This two member is clamped together by a public clamping device 354, and this device also holds one first vacuum chamber 356 and one second vacuum chamber 358 is used for removing the rubbish that is attached on the fiber.Stretch break method fiber 30 at first moves through the hole of first nozzle 350.The effect that it is believed that this first nozzle be drive send fiber forward and the loose long filament on the periphery of the twisting core that second nozzle is formed apply that some is twisted.So fiber moves through second nozzle 352.The effect that it is believed that this second nozzle is to twisting by the long filament in the fiber core of first nozzle in second nozzle upstream but does not cause between the long filament in yarn and entwine.1987 No. 3 189-219 page or leaf publication of a kind of like this understanding and textile research institute journal, consistent by the argumentation of the operation of disposing about the two spray apparatus of Murata in the article that is entitled as " joining in the yarn twisted " that P.Grosberg, W.Oxenham and M.Miao write with aerojet.This article comprises two parts: the experimental study of I. air-jet spinning; II. twisted distribution and twisted adding rate in jet twisting.356 of first vacuum chambers also can be communicated with vacuum source in a side 362 by fluid near first nozzle, 350 ports of export, are communicated with atmosphere at opposite side 364.The air that flows to opposite side 364 from a side 362 is crossed fiber path, can remove long filament and the polymer or the coating dust of loose fracture from it.So fiber moves through second nozzle 352 and strains the opening 366 and second vacuum chamber 358 by one.Back both is near the port of export 368 of second nozzle 352.Second vacuum chamber 358 comprises a tension groove 370 along its length, and this groove can be covered by a cylindrical cover (not shown) after tension.This lid can make this groove be capped or be uncovered around outer surface 372 rotations of clamping device 354, and outer surface cooperates with lid for this chamber of cylinderical surface around this chamber 368 at that time.Second vacuum chamber is at a side 374 and a vacuum source, and tension groove 370 (when this lid unlatching or not the time) and termination 376 and 378 can be communicated with fluid with atmosphere.Air can be from the termination 376 and 378 flows through groove 370 and flows along fiber path, thereby can remove long filament and the polymer or the coating dust of loose fracture from it.As the operation of twisting with the fingers element 83a do not rely on first and second vacuum chambers, thereby but this two Room can make element keep clean can use reliably.

The gas that first nozzle or injector elements 350 have a supercharging is air preferably, is fed to annular channel 382 by pipeline 380 and leads many Compressed Gas raceway grooves again as 384 and 386.Raceway groove 384 and 386 and diameter be d 1Spinning hole 351 intersect, tangent with known pattern, and pass through the direct of travel in this hole with an angle 388 oblique fibers in a position and aperture.The inlet port 389 in the hole 351 of first nozzle 350 can be a straight cylindrical shape or can be that the conical of band gradient also can comprise that breach is twisted in intrastitial propagation so as to influencing.Second nozzle or twisting element 352 have air to be fed to many Compressed Gas raceway grooves that lead again in the annular channel 392 as 394 and 396 by pipeline 390 equally, and these raceway grooves and diameter are d DHole 353 intersect.First nozzle 350 have one from the termination 360 to raceway groove as 386 characteristic distance l 1, and second nozzle 352 have one from entrance point 398 to raceway groove as 396 characteristic distance l DFirst nozzle 350 and second nozzle 352 are spaced apart with a distance " a ", this distance " a " is to measure between the joining in the spinning hole of Compressed Gas raceway groove and each nozzle, and can regulate according to the concrete fiber that will process, can use bigger distance for the fiber that average filament length is big, can be with less distance for the little fiber of average filament length.First and second nozzles 350 and 352 adjustable grounds are clamped in securing member such as dog screw (not shown) makes the adjusting of distance " a " carry out easily in the public clamping device 354.Perhaps each nozzle can have independently clamping device and turn up the soil at interval and is installed in (not shown) on the frame.For any flow process that is used for fixed discontinuous filament fiber, when average filament length greater than 4.0 inches, during more preferably greater than 6.0 inches, once shockingly found to be set to when being directly proportional with the average filament length of fiber when distance " a ", the intensity uniformity coefficient of yarn can reach maximum.

Consult the equipment among Figure 11, pneumatic twisting element 83b is placed on replacement device 83a in the consolidation zone 38 and inhales a device 220 and taken away.

Consult Figure 28 once more, first nozzle 350 is set as far as possible near niproll group 148a (Figure 11), from jaw to first nozzle gas raceway groove 384 and 386 and the position of intersecting, spinning hole 351 be about 1.0 inches.Second nozzle be set from the said position of first nozzle to second nozzle gas raceway groove 394 and 396 and the position of intersecting, spinning hole 353 be various distances " a ".

Shown in Figure 35 for having the yarn strength figure of average filament length for the yarn of " Avg ", each average length is pressed Figure 28 different interval " a " between the gas raceway groove in first and second nozzles 350 and 352 respectively measure yarn strength as data point.On each distance " a ", get several sample of yarn and draw mean intensity number in the gram/dawn (gpd) with the LeaShi product basis.For the curve that indicates 8.0,8.9 and 17.5, corresponding to this intensity peak respectively, it is the yy inch that the distance between nozzle has a particular value as we can see from the figure.Relatively this yy value and the average filament length A vg that wants processed yarn can get ratio avg/yy, can be used to select suitable " a " value in this ratio.Several different length of yarn are repeated this test, and the scope that draws " a " value is for from 0.74avg to 1.53avg, or more excellent in 0.5avg arrives 2.0avg, and getting it average is 1.1avg than the figure of merit.These results will further discuss in conjunction with test 20-23 below.Another test (not shown) wherein second nozzle rests on first nozzle is moved near second nozzle, the fixed yarn of result has low intensity value, so we think that important relation is the distance between nozzle and does not lie in the distance that second nozzle leaves niproll.

Consult Figure 11, fixed yarn is led on the up-coiler 222 after roller group 74a.Between roller group 74a and up-coiler 222 a suction silk device jet pipe 224 and a trough of belt deflector roll 226.Up-coiler has the rocking bar and the fluted roller 228 that are attached on the controller (not shown) and is used for controlling up-coiler speed; There is a transversing gear 230 to be used for making the axis walking of yarn 32 along yarn package 232; Also has a driven shaft.Up-coiler has traditional design, and the expert knows, does not need to illustrate separately.

Flow process shown in Figure 11 has all various function sections, carries out on the straight line path basically.Shown in the function section comprise that drawing zone 124, first fracture zone 34, second fracture zone 36, draw zone 144 and consolidation zone 38 all from left to right arrange on a line, fiber is followed a basic straight path by each functional areas, each path, functional areas forms a unit path vector (has the vector that direction and quantity equal), the direction that this vector is advanced at fiber has a stature, also has a tail.This flow process can be brought into play its function well but need account for a lot of Horizon areas.For the manufacturing machine in the factory, optimal is long-pending with ground level to be very important to the reduction expense.Figure 32 illustrate equipment that a stretch break method flow process uses wherein fiber arranged that by the path of one or more functional areas the path vector that makes in first functional areas places tail ground with the path vector tail in the next order functional areas with turning back, form 45 between the two and spend, can be the Horizon area that flow process causes a compactness like this to the angle of 180 degree.

Consult Figure 32, the equipment of breaking has a drawing zone 402 between roller group 404 and 406, one in first fracture zone between roller group 406 and 410 408, one second fracture zones 412 between roller group 410 and 414 groups, and consolidation zone 416 between roller group 414 and 418.Fixed yarn is wound onto in the up-coiler system at 420 places.As the equipment among Figure 11, equipment 400 also comprises in a heater 140, the static and bar 186, vortex injector 188 and 208, consolidation device 83 as 83a (Figure 26 and 27) or 83b (Figure 28) and the various injector that other drive forwards, deflector roll, niproll etc.In addition, between the heater 140 and first fracture zone 408, a heat screen 417 is arranged.In order to make the flexibility of various products, 419 places after drawing zone 402 before first fracture zone 408 are provided with second fibre feeding.421 places after second fracture zone 412 before consolidation zone 416 are provided with feeding to the position of the 3rd fiber.During operation, 424 places enter the equipment of breaking 400 in the position to feed the creel never be illustrated to fiber 30, are that 425 and tails are the direction of 427 path vector 426 along having a stature.Path vector is not the vector of functional areas, does not also pass through any processing on this aspect because fiber is just transported to.Fiber 30 moves through roller group 404 and is drawing zone 402 along the functional areas that path vector 428 is advanced by drawing of fiber.So fiber 30 moves through roller group 406 and i.e. first fracture zone 408 along path vector 430 functional areas by fracture usefulness.So fiber moves through roller group 410 and i.e. second fracture zone 412 along path vector 432 functional areas by fracture usefulness.So fiber moves through roller group 414 and be consolidation zone 416 along the functional areas that path vector 434 is advanced by fixed usefulness.Fixed yarn 32 is reeled at up-coiler 420 then and is packed.

Figure 33 A, B and C are illustrated in the arrangement of the vector that formation is turned back between each path, functional areas.In Figure 33 A, functional areas path vector 428 in turn and 430 by tail to tail put together.The tail that the tail of path vector 430 is placed with path vector 428 exists jointly, and the angle between two straight line vectors marks with 436 and is about 180 degree.In Figure 33 B, functional areas path vector 430 in turn and 432 tail are mutually common to put together with existing, and the angle 438 between two straight line vectors is about 90 and spends.In Figure 33 C, functional areas path vector 432 in turn and 434 tail are mutually common to put together with existing, and the angle 440 between two straight line vectors is slightly larger than 90 and spends.If in breaking equipment, have only two functional areas: a fracture zone and a consolidation zone, the path vector 430 of fiber in first fracture zone 408 extends along a direction, path vector in consolidation zone 416 434 by turn back along one with the fracture zone in the path oppose, become the directions extensions of 180 degree basically.Thereby can arrange compactly like this and dwindle floor space.All functional areas in turn might not need to turn back, but in order to save occupation of land, have at least two sections in turn fiber path should turned back when a section moves towards next section.

This fiber is placed tail ground with the next path vector tail of functional areas in turn by the path vector that is about in first functional areas of turning back in the path of functional areas, spend to the angle of 180 degree thereby form 45, can make equipment floor space compactness when implementing to break flow process.Just have a plurality of turning back and angle as more than two functional areas the time, the path system of turning back of the present invention can form in turn, and at this moment all with 90 degree or more mostly be suitable, are preferably 180 degree or more in the absolute value sum of each angle between the functional areas that continues.Layout shown in Figure 32 is just broken a kind of layout of turning back of flow process, and the notion in the path of turning back can be applicable to other other layouts of breaking process and path vector.

The yarn that the equipment of Figure 11 is produced is discontinuous filament and short staple yarn, and its dawn number can be used for the terminal use of textiles immediately, except that traditional dyeing or similar procedure, does not need further preparation.The line density of staple fibre product typically was approximately equal to or less than for 1000 dawn, perhaps changed a mode, and for each cross section has the short fiber yarn of 500 or less long filament, line density can be greater than 1000 dawn at that time.It is believed that and it should be noted that this flow process can use the fiber in bulk operation than Denier economically, can save expensive coiling work step like this and can use the fiber that is not stretched that this fiber is difficult to successfully sometimes its packing of reeling.This point is different with the sliver breaking device of the 55b patent of top theory.In bulk feeding to fiber 30 is used to break operation and the technological process of the present invention that produces consolidated yarn 32 is considered to particularly advantageous.Such process comprises: extract fiber out with the speed greater than 1.0 meters/minute in the container of continuous filament fibers in bulk, the dawn number of fiber is between 2000-40000, the fiber that container keeps is the 10-200 pound, fibre feeding is arrived in the fibrous fracture district, in a predetermined section length, make fibrous fracture by the speed that increases fiber greater than 2.0 speed ratio, at the downstream of fracture zone consolidation fibre, just can form short fiber yarn.Be preferably in before the broken fiber, the speed that improves fiber in the drawing zone of upstream, fracture zone in predetermined section length makes its annealing with tensile fiber and with the fiber heating.

The most handy improved method operation staple fibre frame of fiber in bulk obtains most economically.This machinery has an independent polymer supply system to feed to give a plurality of spinning position, and these positions combine usually, thereby the tow products of the big dawn number made can be collected in the container so that be transformed into staple fibre later on.Figure 29 illustrates such system, and staple fibre frame 500 for example has 10 positions as 502,504,506,508 and 510 each positions.The polymer that this machinery provides is from an independent confession source.The tow products 512 that all these positions are combined into a big dawn number by in bulk in a bulk container 514.In traditional staple fibre converting process flow process, keep the capacity of product surpass 1000 pounds container 514 also with other container combination, the product that is kept is passed through to change flow process 516 together, cause staple fibre at last, can in carded, combing, spinning unit 518, be spun into yarn.

Consult Figure 30 now, our improvement is improved staple fibre frame 501 pipes that will have at least about 10 spinning positions, make it produce the tow products of a plurality of low dawn numbers simultaneously rather than produce the independent big dawn and count tow products, and each low dawn counts product and all is less than the big dawn and counts about 20% of tow products.In Figure 30, can imagine at least two positions, best at least 5 positions, for example position 502,504,506,508 and 510 will produce other low dawn and count tow products, and the tow products that big dawn number can be continued to produce in remaining 5 or more position, perhaps consult Figure 31, all positions on the improved staple fibre frame 503 all can produce other low dawn and count tow products.This single low dawn counts tow products 30 and has at least 500 fibers and be collected in the single container 160 in the spinning position, and this container can keep about 20 (~9.07 kilograms) to count tow products to the low dawn of 200 pounds (~90.72 kilograms).Being used for collecting the facility that the single low dawn counts tow products is device 524 in bulk or up-coiler (not shown); Preferably use the device in bulk product that will not be stretched to collect in the container 160, make this product can be stored, transport and extract out so that further processing.The packing that is wound on the tube core from up-coiler also is a kind of container, can be stored, transports and extract out so that further processing from this container products.

The method of new operation staple fibre frame comprises that also at least one is made feature that spinning position that the low dawn counts product changes fiber product makes its fiber product feature be different from remaining to make the low dawn and count the spinning position that product or big dawn count product.The fiber product feature of this change can comprise every different filament deniers, different coating, owing to the different color that causes at the direct dye injection in spinning position, different filament cross or other fiber differences that on indivedual spinnings position, can have usually.

The new method of operation staple fibre frame comprises that also providing a facility to come to count tow products from least one low dawn of spinning position processing makes it be transformed into the yarn product of spinning.This being preferably by the of the present invention of fiber containers 160 feed in bulk at the facility shown in Figure 30 and 31 breaks mechanical 522.Perhaps, ' 463 patent that this machinery can be and authorizes Minorikawa's or authorize 778 patents of Adams or similarly continuous filament fibers can be transformed into the machinery of discontinuous filament and short staple yarn.Can supply the needs of breaking machinery general 10 spinning positions such as position 526 on 522 in each position on the staple fibre frame as 502, thus each a plurality of spinnings position all arranged many break machinery as 522 and 522a can be by independent staple fibre frame 500 delivery of fibers.

Can use that United States Patent (USP) 4,221,345 is disclosed in bulkly to be put or install in Figure 11,30 and 31 the bulk container 160 with the device shown in Figure 13 and 14 feed for yarn 30.Device in bulk 236 shown in Figure 13 have a deflector roll 238, dummy roll 240, driven roller 242, one inhale silk device jet pipe 244, Fiber Distribution rotor 246, rotor driver 248, a container 250 and a container oscillator 252.Fiber 30 can be from continuous artificial filament's staple fibre frame such as the staple fibre frame 501 or 503 in Figure 30 and 31.Deflector roll 238 is roller 240 and 242 with the assembly that fiber directs into dummy roll/driven roller, thereon shown in arrow 254 and 256 fiber feed along the direction of arrow 258 be given to inhale silk device jet pipe 244 before winding one whole circle at least.Fiber is inhaled that gas in the device jet pipe is pushed the admission passages 260 in the rotor 246 to and rotor 246 is rotated continuously by rotor driver 248.Fiber moves through rotor 246 and leaves by channel outlet 262.So fiber drops in the container 250 with spiral path 264.Along with the part of container gradually by fiber filled, the container oscillator moves container below rotor is laid it gradually by front and back spirality back and forth fiber filled lentamente.This device in bulk can make it can be from container with the at a slow speed taking-up consistent with breaking speed to deposit like this with the speed operation of traditional spinning position consistency and with fiber.

Figure 14 illustrates the detailed section view of rotor 246, this rotor has a body 266, and 260 of admission passages are on the pivot at body 266 tops and be connected to channel outlet 262 by the passage 268 of an angulation and make fiber 30 (Figure 11) and come the gas of self-priming silk device jet pipe 244 (Figure 13) easily to move through.There is a balance pipe 270 to be located at the vibration of channel outlet 262 opposites when coming balancing rotor and reducing rotation.

The short fiber yarn that process shown in Fig. 1,8 and 9 uses the equipment of Figure 11 to produce has the short fiber yarn that the line density that was less than or equal to for 1000 dawn or each cross section have 500 or less long filament.A kind of like this yarn is operated and the filament length that has a uniqueness when a kind of specific stretch break method yarn is provided distributes as mentioned above like that when the fracture zone.This unique stretch break method yarn has filament length and filament length scope of a specific average filament length, a maximum.This stretch break method yarn per inch has a significant figure purpose filament end.A sizable percentage in these numerous long line end heads is the projection termination that the middle body from yarn stretches out, and can give that yarn is a kind of to make us desirable " feel ".In a more excellent embodiment, yarn has the average filament length (relative with weight average) of numerical value greater than 6 inches, the maximum length of 99% long filament is less than 25 inches, and middle 98% filament length forms the length range more than or equal to average length.The minimum length of 98% sample in the middle of the maximum length of 98% sample deducted in the middle of this scope equaled.Yarn also can be represented its feature like this: fixed artificial fibre has the different discontinuous long filament of length, these long filaments are along the length interlacing of yarn and keep the globality of yarn, wherein the average length avg of long filament is greater than 6 inches, is characterized as 5% to less than greater than average length avg 1.5 times of the length of 15% long filament and the filament length of fiber distributes.Preferably this filament length distributes and also has 5% to arrive less than 15% filament length less than 0.5avg.

Figure 15 illustrates the filament length distribution map of the yarn of making according to following procedure parameter:

e b=3.5, go the feeding of drawing zone to yarn

e b=0.247, after stretching, enter the yarn of first fracture zone

e b=0.1 (estimated value when entering second fracture zone)

L1=51.0 " (~129.54 centimetres); L2=16.9 " (~42.93 centimetres); (L2=0.33L1)

D1=3;D2=2;(D2-1)/(D1-1)=0.5

Stretching speed ratio D4=4.2

Drawing zone length L 4=112 " (~284.48 centimetres)

Draft temperature=188 ℃ are 1 " on (~30.48 centimetres) long contact-making surface

Feed to material be one 9147 dawn, 6.6dpf continuous filament yarn nylon fiber is from fiber containers in bulk.

On behalf of the filament length of actual sample of yarn, the histogram of Figure 15 distribute and is marked with 271.The long filament section is to pull out from fixed preceding fiber, therefore takes away easily.Do not use drawing-off.Filament length is to be used in US 4,118, is entitled as that " average fiber length ", " fiber length distribution " and the illustrated processes of part such as " fibre length histograms " obtain in 921, these parts at this paper by with reference to quoting.Because measurements and calculations are known 192 long filaments approximately from second fracture zone in the cross section of fiber, therefore take 500 long filaments away from the new termination of fiber, write down its length and they are organized into groups by 1 inch increment.To these 500 long filaments, 100 long filaments of every batch of usefulness repeat according to said process in " average fiber length ".The result must go out the fibre length among Figure 15 and the histogram 271 of frequency.The modeling of the process identical with the actual tests process is established, and the filament length of prediction distributes as the curve among Figure 15 272.From scheming as seen, the simulation that filament length distributes distributes very approaching with actual filament length.With regard to the actual tests speech, the average filament length of numerical value is 11.0 " (~27.94 centimetres), and just simulation says that average filament length is 11.1 " (~28.2 centimetres).With regard to actual tests speech, the length of middle 98% long filament section is 3 " (~7.62 centimetres) to 18 " (~45.72 centimetres), scope is 15 " (~38.1 centimetres).And simulation speech just, length is 3.5 " (~8.89 centimetres) to 19.5 " (~49.53 centimetres), scope is 16 " (~40.64 centimetres).With regard to the actual tests speech, the maximum length of 99% long filament is 18 " (~45.72 centimetres), and just simulation says that maximum length is 19.5 " (~49.53 centimetres).In these projects the error of the analogue value all actual value 10% within.In addition, length is less than long filament number and the length all measured and simulation greater than the long filament number of 1.5avg of 0.5avg.The result who measures for less than 0.5avg be 8.2%, greater than 1.5avg is 5.0%.And Simulation result for less than 0.5avg be 11.16%, greater than 1.5avg is 10.27%.These analog results are not too consistent with measured value.We think that this is because the measurement result that long filament distributes is insecure, because the long filament of getting in the end that distributes really very little on statistics with regard to the top and bottom of distribution value.It is sampled to have 40,000 long filaments when simulation, comprising many long filaments that are distributed in the end.And in the distribution of measuring, just only 500 long filaments are measured altogether, and the long filament that is distributed in the end certainly seldom.Change this inconsistent situation, perhaps can in the sample of measuring, take more sample.Data among Figure 15 are also listed in Table I.

The actual tests value and the analogue value are all in the limit that yarn product of the present invention requires to reach, just like following:

Average filament length=11.0 " (~27.94 centimetres) and 11.1 " (~28.19 centimetres), this value 〉=6 " (~15.24 centimetres)

Middle 98% scope=15 " (~38.1 centimetres) and 16 " (~40.64 centimetres), this two values difference 〉=11.0 " (~27.94 centimetres) and 11.1 " (~28.19 centimetres)

The maximum length of 99% long filament=18 " (~45.72 centimetres) and 19.5 " (~49.53 centimetres), this two value is all≤25 " (~63.5 centimetres)

Less than long filament section=5.0% and 10.27% of 1.5avg, this two the value all 5% and<15% between

Less than long filament section=8.2% and 11.16% of 0.5avg, this two the value all 5% and<15% between

Following Table I illustrates other simulated operation conditions that comprise some Comparative Examples simulation and the scope that various operating parameters are shown, and these scopes are all in limit of the present invention.The actual result and the analog result that also comprise some actual tests in the table.

Example CE1 and CE2 are the comparative simulation example with overall ratio Dt=25 operation.In routine CE1, fracture zone length L 1 is 30 " (~76.2 centimetres), the percentage that double fastener is held long filament is low.The long filament of CE1 is distributed among Figure 16 and draws, and the maximum length that can determine 99% long filament is all 25 " more than (~63.5 centimetres).In CE2, fracture zone length is 10 ", on average long line length is less than 6.0 ", when intersection is used to when fixed, this value is considered to cause the low-intensity yarn.The long filament of CE2 is distributed among Figure 17 and draws, from scheming to go up the maximum length of visible 99% long filament less than 25 " (~63.5 centimetres), this ratio CE1 improves.Because to hold the percentage of long filament all low for double fastener in these two Comparative Examples with single fracture zone, can expect that this two example has the property grasped problem when operation.The operability problem is for less than 20 when the test similar to simulated conditions carried out in single fracture zone " section length of (~50.8 centimetres) can take place near 20 the time at speed ratio, for 10 " section length of (~25.4 centimetres) can take place near 5 o'clock at speed ratio.

Example A, B, C, D, E and F are the simulation examples of carrying out under overall ratio Dt=25.Example A is illustrated in second the fracture zone in and adopts high speed than D2=10, and the result causes in second fracture zone double fastener to hold the low percentage of long filament, though this percentage is bigger by 50% than the percentage in single fracture zone in the Comparative Examples, but lower.For example A1 illustrates the speed ratio that the speed ratio of second fracture zone is reduced and increase by first fracture zone increases to obtain suitable (D2-1)/(D1-1)=2.0.Can expect that this will improve the operability of routine A.Situation shown in the example B is that first and second fracture zones are all with 5 operations of identical speed ratio.The double fastener percentage of holding long filament can obtain good result like this, but in second fracture zone low with to the property grasped problem more easily in this district's generation.Example B1 illustrates the speed ratio that reduces by second fracture zone and increases the double fastener that the speed ratio of first fracture zone makes two districts all have identical high percentage and holds long filament, can expect to improve the operability of second fracture zone.The approximation of the Ndg/Nuc in two districts is to obtain when (D2-1)/(D1-1)=0.7 among Fig. 4.Example C adopts the influence of high speed ratio in first fracture zone, compare with routine A and routine B, and this will reduce the percentage that double fastener is held long filament.But when D1=10, double fastener is held long filament percentage and still is higher than among the routine A when D2=10 the double fastener in second fracture zone and holds long filament percentage.This point can be supported from the real data Figure 10 A.Can see that from this figure D1 is 7.5 at that time corresponding to the Dt=42.8 of the maximum maneuverability point of the optimal value 0.7 of (D2-1)/(D1-1), D2 is 5.7.Therefore appear to double fastener hold the relevant operability problem of long filament in second fracture zone with low speed during than operation than in first fracture zone, taking place easily.The long filament of example C distributes shown in Figure 18.Average length=6.51 wherein " and (~16.54 centimetres) (>=6 ") (~15.24 centimetres); Middle 98% scope=10 " and (~25.4 centimetres) (>=6.51 ") (~16.54 centimetres); Maximum 99% filament length=11.5 " (<=25 ") or~29.21 " (<=63.5 centimetres).To length<0.5avg and>analog result of the long filament number of 1.5avg is 13.43% for<0.5avg's,>1.5avg's is 12.06%.This has just proved that per inch of the present invention has the filament end number of suitable number for example.Example D, E illustrate resulting similar with C to routine A, B respectively result when using the first and second long fracture zone L1 with L2 with F, owing to all be L2=0.33L1 under each situation, therefore double fastener being held long filament percentage seldom influences.And average filament length increases as expection.

Example G, H, J and the simulation example of K under higher overall ratio Dt=30, moving.Adopt different section length, but routine G and H are still had L2-0.33L1, this two example can compare with routine B and C respectively with regard to double fastener is held long filament percentage, because Dt increases seldom, is not enough to reduce too much percentage.The long filament of example G distributes shown in Figure 19.This example ratio C has long average length=10.1 " (~25.4 centimetres), centre 98% scope=15 of broad " (~38.1 centimetres) and higher maximum 99% filament length=17.5 " (~44.45 centimetres).To length<0.5avg and>analog result of the long filament number of 1.5avg is 15.49% for<0.5avg's,>1.5avg's is 14.30%.With routine C ratio, routine G has corresponding lower per inch filament end number, also makes this value lower but feed to the minimizing of yarn Denier and the increase of speed ratio.In routine J and K, L2=0.2L1, but this change is little, is not enough to cause too big difference when comparing with routine B and C respectively.

Figure 20 illustrates the summary technological process of Fig. 9, in this flow process since the downstream of draw zone 144 just the upstream extremity of consolidation zone 38 introduce other feeding and can produce new product to fiber 31a.Because fiber 31a does not pass through drawing-off, the long filament in the fiber 31a can be continuous or discontinuous.If what use is continuous filament yarn, they can be the high strength filaments such as the aramid fibre of low elasticity, perhaps they can be elastomeric long filament such as Spandex formula fiber or 2GT (polyethylene terephthalate) (1 of usefulness terephthalic acids esterification, 2-ethylene glycol or 1, the 2-ethylidene glycol) or 3GT (polytrimethylene terephthalate) (with 1 of terephthalic acids esterification, ammediol) polyester fiber.More excellent Spandex formula fiber is that the sort of its elastic filament has greater than about 100% fracture elongation with from what about 50% extension recovered and is at least 30% elastic restoration ratio.These additional fibers 31a can be added in the fiber 30, and fiber 30 preferably includes a kind of polymer such as nylon, polyester, aromatic polyamides, fluoropolymer or Nomax (trade (brand) name of fiber and paper and isophthaloyl chloride, methpenylene diamine raw material) has the Kevlar of continuous filament yarn Aramid fibre once in a product with polyester combination, and have the Lycra of continuous filament yarn Elastomer once in another product with polyester combination.

Figure 21 illustrates the summary technological process of Fig. 9, in this flow process since the downstream 302 of drawing zone 124 just the upstream extremity of first fracture zone 34 introduce other feeding and can make the stretch break method product that makes new advances to fiber 31b.Do not need to stretch and will add in the fiber 30 that has stretched as fruit fiber 31b, it is effective doing like this.Two kinds of fibers all will be ruptured in first fracture zone simultaneously and will be continued the processed together remainder by process.The fiber 31b of this interpolation preferably belongs to the polymer cohort and comprises aromatic polyamides, fluoropolymer and Normex , they are added in the fiber 30, and fiber 30 preferably includes a kind of polymer from nylon or polyester cohort.

Figure 22 illustrates the summary technological process of Fig. 9, in this flow process since the downstream 302 of drawing zone 124 just the upstream extremity of first fracture zone 34 introduce first kind of other feeding to fiber 31b; Also the downstream 300 of draw zone 144 just the upstream extremity of consolidation zone 38 introduce second kind of additional fibers 31a and can make the stretch break method product that makes new advances.Like this can be effectively the property combination of fiber be got up and discuss in conjunction with Figure 20 and 21 as top.A good especially embodiment introduces fluoropolymer to add fiber 31b as first kind, introduces Spandex formula fiber and adds fiber 31a as second kind, adds fiber bond to polyester fiber 30 with these two kinds.This yarn product is the useful textile yarn that the formula hosiery of weaving is used that can be used as.Another kind of product be with discontinuous polyester fiber as be stretched first hello to fiber, and with Kevlar Aromatic polyamides add to feed to enter as first to fiber combinations, broken with polyester fiber, will have the Lycra of continuous filament yarn again Elastomer is fed as second and is entered to constitute the yarn with three components to fiber combinations.

Of the present inventionly break technological process and can be used for mixing the fiber that has been machined into some degree effectively as owing to introduce painted or surface treatment makes fiber have the visible characteristic that some can with the naked eye be discovered.Breaking is an effective way making extraordinary yarn, the work step that can comprise many interpolations, these work steps are needed in traditional staple fibre mixes, at that time at first must with operations such as prescinding (cutting), mixing, carded, combing prepare sliver as among Figure 29 shown in 516 and 518 places.In this traditional system, must prepare a large amount of feeding and make flow process worthwhile, because the cleaning process equipment is very time-consuming behind every batch of production to fiber.And with stretch break method the time, only need prepare a spot of feed to fiber in case with another kind of mixed with fibers.In fact need not clear up the configuration when being converted to another kind of product and mixing on changing creel.This is effective especially when a small amount of color mix yarn of preparation.Consult Fig. 9, the applicant once found to feed the different colored fiber that first kind of colored fiber 31c colored fiber 31d different with second kind can produce two kinds of color mix.So-called different colour is meant two kinds of colours right and wrong white and allochroic variation basically, though wherein a kind of fiber can be white and true qualities, another kind is distinct non-white and allochroic colour.That does like this is intended that two kinds of distinct color combinations, thereby breaks fixed then a kind of new distinct colored ASTM E that causes together 12The standard E-284 of the committee once illustrated and a kind ofly distinguished muted color as the white and the method for true qualities according to brightness measurement, and the brightness of white and true qualities is greater than 90%.Also available CIELAB unit difference colourity and tone come the difference of sense colors, and the difference of distinct colour in CIELAB unit is at least 2.0.At least two kinds of different colours of blended fiber, the brightness of wherein having only a kind of colour are greater than 90%, and the difference of other colours in CIELAB unit is at least 2.0 and just can causes new multicolored yarn to fiber from least two kinds of different feeding.The colour of new yarn and any hello colored completely different to fiber.The colour mixture outward appearance that when further being processed into cloth shape material, presents a kind of gentleness.Can breaking fiber that flow process mixes and also can have other difference such as reflections, absorption, wettability etc. visually with the application.

Figure 23 is the summary elevation view of technological process line among Fig. 1, and it is after consolidation zone 38 that increasing of annealed zone 124a is shown.The annealed zone was once discussed in conjunction with drawing zone 124 in the past, and speed does not change basically when using heating facility shown in Figure 8.The annealed zone being located at the final contraction that can be used for yarn after the consolidation zone must being controlled in the process of setting, is to finish the most direct approach of this target because form after annealing at yarn.This layout also is useful in another case, promptly have two kinds of different fibers and the heat treatment meeting of annealing makes in the yarn each play differential responses and when causing a kind of yarn of special effect, as when the contraction difference of two kinds of fibers and different contraction can produce yarn bulk or multi-turn the time when feeding to fiber.

Figure 24 illustrates a kind of microphoto of long filament of new stretch break method product, and in this product all split in breaking process in the termination 304 of each long filament.Feeding to fiber is the artificial fibre with continuous polyester filament, and polyester filament is produced for E.I Dupont, and trade mark is Coolmax This product is at the US 3,914,488 that authorizes Corrafa and authorize among the US 5,736,243 of Aneja explanation is arranged.Consult 25, the cross section of this long filament shown in it has a width 306, have a plurality of thin portions 314 and 316 to couple together in this width thick 308,310 and 312.People be sure of that the process of breaking can make the thin portion 314 of filament end and held in 316 minutes when breaking long filament.Therefore separately occur in the length 318 at least about three double-length silk width on the termination of long filament one or more thick as 308 just split as 310 and 312 minutes with other thick.It is believed that like this and just can cause the look and feel that in yarn, has more filament end, thereby can improve " feel " of the fabric of making by this yarn.

Table II illustrates according to instruction of the present invention and makes various products, roughly implements the equipment among technological process use Figure 11 shown in Figure 9.The dawn number of feeding to material is about 1 altogether, 500-20, and 000, the dawn number of output yarn is about 100-400.The fiber that is stretched in this flow process is fully stretched usually, and the fracture elongation that therefore enters first fracture zone is about 10%.

Test 1 illustrates the technological process condition that final dawn number is 137 nylon yarn of making.This flow process has a drawing zone, one first fracture zone, one second fracture zone, a draw zone similar to the flow process among Fig. 9 with a consolidation zone.Feed to yarn from 160 among bulk container such as Figure 11 (pointing out with P in Table II), final products are wound onto on the up-coiler as 222 among Figure 11.The gas raceway groove of fixed injector 83a (Fig. 9 and 26) and yarn direct of travel angulation 340 are 60 degree, and this angle is all the same to all tests of using this injector 83a.Jaw spaced apart distance between the roller 150 and 152 of injector outer surface 328 and roller group 148 is about 6.0 inches.It is believed that the yarn that this process is produced has feature of the present invention: average filament length is more than or equal to 6 " (~15.24 centimetres); the maximum length of 99% long filament is less than 25 " (~63.5 centimetres), the length range value that middle 98% long filament section forms is more than or equal to the average filament length value, and has 5% to less than 15% long filament, 1.5 times greater than average filament length on length.

The technological process condition of test shown in 2 with test 1 similarly, a drawing zone, one first fracture zone and one second fracture zone are arranged, roughly be used for making the identical of product shown in Figure 15.Fiber is further processed in draw zone and consolidation zone, forms the yarn at 209 dawn, and product is just accused and finished, and the long filament that this product can be look to having as shown in Figure 15 distributes.

Product shown in the test 3 is made less than 0.1 polymer with coefficient of friction between long filament, and this is a fluorochemical, is made with trade name Teflon by E.I.Du Pont de Nemours company (letter later on is " DuPont ") For selling.The staple fibre Teflon that technological process is produced Product is difficult to make economically with additive method.On roller group 50a, the 60a of Figure 11 and 148a, use " inferior rice eggplant " winding drawn among Figure 1A so as to the slip of controlling fiber in the roller group.Feed to fiber by the supply of 162 among bobbin package such as Figure 11 (in Table II, pointing out) with W.This flow process is not heating or stretching in drawing zone of fiber with test 1 difference.People be sure of that this product has greater than 6.0 inches average filament length and other features similar to test 1.

Product shown in the test 4 is used and similar technological process manufacturing shown in Figure 21, at that time at polyester fiber (DuPont trade mark Dacron ) back that is stretched feeds high-intensity aramid fibre (DuPont trade mark Kevlar at the upstream extremity of roller group 42 (42a among Figure 11) ), so with polyester fiber broken, drawing-off and fixed, produce the blended yarns at 397 dawn.Use " inferior rice eggplant " winding drawn among Figure 1A on roller group 50a, 62a in Figure 11 and the 148a, so as to the slip of controlling fiber in the roller group, because aromatic polyamides needs big pulling force to rupture.People be sure of that this product has and test 1 similar filament length feature.

The product of test shown in 5 used to testing 3 similar technological processes and made, wherein aramid fibre (DuPont trade mark Kevlar ) and fluoropolymer (DuPont trade mark Teflon ) be fed into together not to be heated also in the drawing zone and be not stretched; Drawing zone just is used as easily, and approach is transported to first fracture zone, Kevlar with fiber And Teflon So broken together, drawing-off and fixed, thereby produced the blended yarns at 274 dawn.Use " the inferior rice eggplant " winding of drawing among Figure 1A so as to the slip of controlling fiber in the roller group on roller group 50a, the 62a of Figure 11 and 148a, fluorochemical need more surface contacts and avoids slip because aramid fibre needs big pulling force could rupture.This yarn is particularly suitable for making reinforced fiber and can be used as industrial synchronous gear wheel band, and high strength and low wearing and tearing all are much accounted of at that time.It is believed that this product has and test 1 similar filament length feature.

The product of test shown in 6 used to testing 5 similar technological processes and made, wherein aramid fibre (DuPont trade mark Kevlar ) and high temperature fiber (DuPont trade mark Nomex ) be fed into together in the drawing zone, be not heated yet and be not stretched; Drawing zone only is intended for easily, and approach is transported to first fracture zone, Kevlar with fiber And Nomex So broken together, drawing-off and fixed, thereby produced the blended yarns at 230 dawn.Winding is so as to the slip of controlling fiber in the roller group to use " the inferior rice eggplant " of drawing among Figure 1A on roller group 50a, 62a in Figure 11 and the 148a, because aramid fibre needs big pulling force to rupture.It is believed that this product has and test 1 similar filament length feature.

The product of test shown in 7 used to testing 3 similar technological processes and made, and wherein aramid fibre (DuPont trade mark Kevlar) is fed into not to be heated also in the drawing zone and is not stretched; Drawing zone just is used as easily, and approach is transported to first fracture zone with fiber.Use " inferior rice eggplant " winding.Produce low dawn number and be 101 Kevlar Yarn, this yarn additive method is difficult to make economically.It is believed that this product has and test 1 similar filament length feature.

Product shown in the test 8 is used to testing 4 similar technological processes and is made, and different is at polyester fiber (DuPont trade mark Dacron) upstream extremity fluorine-contained polymerisate fibre (the DuPont trade mark Teflon of back at roller group 42 (42a among Figure 11) that be stretched ) fed, so fluoropolymer and polyester are broken together, drawing-off and fixed, produce the blended yarns at 278 dawn.This product can be used to make socks can be reduced wearing to carry on person's pin and form local eminence.It is believed that this product has and test 1 similar filament length feature.

Technological process shown in the test 9 is similar to test 1, and different is the used polyester fiber that is.The dawn number of the yarn of making is 274.It is believed that this product has and test 1 similar filament length feature.

Product is used to similar technological process shown in Figure 20 and is made shown in the test 10, wherein at polyester fiber (DuPont trade mark Dacron ) be stretched, break with drawing-off after, at elastomer (the DuPont trade mark Lycra of the upstream extremity continuous filament yarn of roller group 148 (148a among Figure 11) ) fed.Lycra Be attached to Dacron Be elongated before going up extend to about 100%, together fixed then, Lycra It is continuous that long filament still keeps.Lycra when under the yarn of finishing is not having the situation of tension force, being held Just shrink and become the yarn of bulk multi-turn with high flexibility.

Technological process shown in the test 11 is similar to test 9, and different is that polyester filament has cross section as shown in figure 25, thereby produces the yarn at 277 dawn with the termination of splitting shown in Figure 24.

Process shown in the test 12 is similar to test 1, and different is to feed fibers different by two kinds to fiber, the different colours of each tool to constitute.Two kinds of colored fibers just are combined before stretching, are stretched together as single bundle fiber then and break.First kind of fiber is pink clearly, and second kind of fiber is purple, it is believed that these two kinds of colours colored difference that all to be brightness have less than 90% non-neutral look and they is at least 2.0CIELAB unit.The colour of the yarn that causes at last obviously is different from any colour of feeding to fiber.People be sure of will have the outward appearance of colour mixture when this yarn is made into fabric.

The technological process of test shown in 13 is similar with test 12, and pink fiber is considered to neutral brightness that different is is greater than 90% light gray fiber replacement.The yarn that causes has and obviously is different from any and feed gives colored colour, and yarn itself has the outward appearance of colour mixture clearly.Technological process shown in the test 14 is similar to Figure 20's, wherein Kevlar First broken (as testing 7) feed for fiber, and have the Kevlar of continuous filament yarn The second fiber just in time upstream of the roller group 148a in Figure 11 is fed.Continuous filament yarn Kevlar Discontinuous to break long filament fixed, constitute the dawn number and be 311 enhancing short fiber yarn.

Technological process shown in the test 15 is similar to Figure 22's, and wherein the Teflon fiber is fed in the upstream of roller group 42 (42a among Figure 11) (as test 8), and Lycra Fiber is fed in the upstream of roller group 148 (148a among Figure 11).Teflon The Dacron of fiber and stretching Fiber is broken and drawing-off together, and the discontinuous fibre of this mixing is had the Lycra of continuous filament yarn then Consolidated fibers is as testing described in 10.So just, can make can yarn that extend, bulk and low friction, and suitable manufacturing can reduce the stretch socks of local eminence.

The technological process of test shown in 16 is similar with test 1, wherein two separate hello be supplied to fiber and cause big dawn data to enter in the drawing zone in this flow process to fiber near 20,000 dawn.Use two humidity provinces on the heater 140 in drawing zone in Figure 11.First district has 24 inchages at 100 ℃, is connected on thereafter second district and has 12 inchages at 188 ℃.Total flow process speed ratio surpasses 70 * (70 times), produces the yarn at 277 dawn.

Test 17 illustrates a product of making according to explanation of the present invention, particularly uses the equipment among Figure 11 to implement technological process shown in Figure 8.Because this flow process do not use draw zone, so draw zone 144 among Figure 11 and roller group 148a must remove and consolidation zone 38 is moved to position near roller group 62a.Use the consolidation device among Figure 28 or be called as the tandem injector device, flow process always be stretched as 48, make the product at 192 dawn, show the low L2/L1 ratio that uses 0.25.Table III is listed the parameter of tandem injector.

17 roughly the same crosswise jet devices that have been to use Figure 26 and 27 of technological process that test 18 is used and test.Feed giving yarn respectively is that the black nylon tow at 6280 dawn constitutes by two strands, and they were just combined before entering drawing zone, and the dawn number of the final yarns that causes is 186.This process flow operation always be stretched as 67.4, output speed can be up to 303 yards/minute, this speed near the test used machinery rate limit.Surpass 500 yards/minute higher speed if use the higher machinery of technological process of the present invention and speed to be expected to reach.

Test 19 illustrates and tests 18 similar results, and final at that time output speed is 269 yards/minute, makes the Dacron at 198 dawn Product.

Test 20,21,22 and 23 all be to test 17 similar configurations under carry out, purpose is to examine or check optimum distance " a " between the nozzle of consolidation device among Figure 28.Each test all is configured to produce the yarn of being determined by simulation with different average filament length.Each average filament length is all tested several times, changed the distance " a " between the nozzle of consolidation device at that time, the distance that the first nozzle N1 is rested on the crosspoint of leaving gas passage and fiber holes is on 1.72 inches the position; Move second nozzle and just can change " a ", then each fixed sample of yarn is collected,, in the gram/dawn intensity is noted with regard to each position of second nozzle with the intensity of each position sample of Lea product process measurement to each position.

Test 20 is configured to produce simulation, and determined to have average filament length be 8.9 inches yarn.The result draws to indicate 8.9 curve in Figure 35.As test 20 situations about being write down in Table III, at this moment the ratio of a/avg was 1.03 when maximum intensity occurred in injector spacing " a " and is 9.2 inches.This is tested used condition also carried out the simulation that long filament distributes, the result tests under 20 in Table I and illustrates.The distribution of long filament is pointed out in simulation, greater than 1.5avg reach 12.4%, reach 14.7% less than 0.5avg.

Test 21 as test are carried out 20, are that to be changed as a means of producing average filament length be 17.5 inches Dacron to fracture zone length Polyester fiber.In this set condition also the high L2/L1 ratio with 0.58 carry out.The result draws to indicate 17.5 curve in Figure 35.Maximum intensity occur in injector spacing be 13.0 inches as in the Table III test 21 contained, at this moment the ratio of a/avg is 0.74.Also long filament is distributed with this experimental condition and to simulate, 21 of tests are contained in result such as the Table I.The distribution of long filament is pointed out in simulation, greater than 1.5avg reach 12.4%, reach 13.9% less than 0.5avg.

Test 22 as test are carried out 20, are that to be changed as a means of producing average filament length be 6.4 inches Dacron to fracture zone length Polyester fiber.The result draws to indicate 6.4 curve in Figure 35, this curve does not have significant maximum intensity value, basically be smooth, just there is place's intensity to drop to suddenly and is about 0.8, this value estimates, because the sample of making in this distance that is about 4 inches is very weak can not be carried out the test of Lea by coiling to whole strand.This may be since when little average filament length injector spacing intensity and indecisive or this test are still had the problem of not explained.Also under this experimental condition long filament distributed and simulate, the result tests 22 and lists in Table I.Simulation points out that long filament distributes, greater than 1.5avg reach 12.3%, reach 13.9% less than 0.5avg.

The arrangement of test 23 is not allow fiber rupture in first fracture zone, only allows it rupture in second fracture zone, so as to simulating the flow process of single fracture zone.This test is configured to produce that to have average filament length be 8.0 inches yarn.The result draws to indicate 8.0 curve in Figure 35.23 of tests are contained when maximum intensity occurs in injector spacing " a " and is 12.2 inches such as in the Table I, and a/avg ratio at that time is 1.53.Also long filament is distributed under this experimental condition and simulate, the result test 23 and lists in Table I, simulate point out greater than 1.5avg reach 18.4%, reach 18.3% less than 0.5avg.Though this product product feature made from fracture zone is outside the limit of the present invention of using two fracture zones, but it shows that injector spacing has an optimal value to the yarn strength of the best, and can carry out in the multiple manufacturing process of average filament length greater than 6 inches yarn.

Viewing test 20,21,22 and 23 result, distance values scope between first nozzle and second nozzle is 0.74 to 1.53 or is about and has average filament length about 0.5 to 2.0 times greater than the average filament length of about 6.0 inches fiber/yarn, it is average to get three " a " values, and the optimal value that can get " a " is about 1.1avg.Though test 22 neither one point of maximum intensities, but it has an intensity to reduce a little, if this intensity reduce a little to abide by instruction of the present invention be avoidable, when layoutprocedure, nozzle can be located on more excellent " a " value 1.1avg, " a " value that draws like this is 1.1 * 6.4=7.0 inch (~17.78 centimetres), and the intensity that can cross 5.0 inches (~12.7 centimetres) reduces the position.

The configuration of test 24 is similar to test 17, uses the consolidation device among Figure 28, and the L2/L1 ratio is decided to be 0.35, and the average filament length that the yarn of producing has is 6.7 inches.

Test 25 is used and test 17 similar technological processes.In test to feed to material be the elastomeric yarn of bi-component, wherein each long filament all has a circular cross section, half of cross section is the 2GT polyester, second half is the 3GT polyester.This material of feed giving once illustrated authorizing in the United States Patent (USP) 3,671,379 of Evans etc., was here quoted by reference.The relevant patent of authorizing other people also has 3,562,093; 3,454,460 and 2,439,815.Therefore two different polymer in cross section have different shrinkage characters behind spinning, this fiber becomes curling fiber and crimped filament or the resilient tissue that spirals after heat treatment.Before the potential elasticity with the heat treatment activation fiber, fiber still has the flexible type of remarkable quantity to curl, so that the past, problem took place when using traditional combing and carded device fabrication short fiber yarn.It will be not known in textile industry that the result makes the short fiber yarn that it is believed that this bicomponent fiber, the gauze line how long that causes is springy very, have sizable elasticity never pulling force to maximum pull, institute's flexible being removed and long filament does not have plastic deformation at that time.This is flexible to be characterized as to curl and to represent (CD) percentage.Should curl represents available damp and hot the promotion, and can measure according to the guide rule in above-mentioned 379 Hes ' 460.The yarn of finishing must be heat-treated after breaking to recover its potential elasticity and to obtain its final elastic characteristic.

Test 25 illustrates the process condition of the bi-component yarn of making 2GT polyester and 3GT polyester components (pointing out with BC23), the final dawn number of yarn is 160, this flow process has a heat-treatment zone, one first fracture zone, one second fracture zone, with a consolidation zone, similar to the flow process among Fig. 8, do not use draw zone.Feed to the bobbin package of yarn from 12 100 dawn yarns, each pack to Figure 11 in 162 similar.Should feed to yarn by predraft, not through Overheating Treatment, though fiber has some parts elasticity or curling, but its potential elasticity was not brought into play.The final yarns product is wound onto on the up-coiler shown in Figure 11 222.Employed consolidation device is the tandem injector among Figure 28.Strainer 164 is adjusted to can provide enough pulling force that all part elongations (curling) are removed to yarn from feeding at roller 168 places on feeding to yarn.Yarn is keeping pulling force but the condition of non-elongate filaments is heat-treated to 180 ℃ by fiber heater 140.Though this fiber does not stretch in drawing zone 124, surprisingly fiber must heat the good operability that can remain in the fracture zone.Yarn is broken and is broken in section D1 and D2, does not have drawing-off ground to be sent to fixed injector 83b then, forms the yarn at 160 dawn, is wound up into then on the packing at 222 places, applies enough pulling force during coiling the elongation in the yarn is removed basically.In order to bring into play the elasticity of yarn, yarn must be heated to about 100 ℃ and make the elastomeric yarn tissue (having wrinkle and curling) that its forms spirality and spiral and have good bulk and elastic restoration ratio.At this moment heating can finish in the work step that separates or yarn can be made into fabric and heat is provided by the coloration of textile materials process.The discontinuous filament yarn that curls is considered to have the curling of about 35-40%, and this is to measure according to illustrated program in 379 patents of authorizing Evans etc.Wrinkle in the yarn that it is believed that in this flow process to be produced and curling because the mixed and disorderly fracture of long filament and being loosened are very useful when therefore this line yarn has the few stretch break method spun fabric of " orange skin " (fabric face has as the orange surface the outward appearance with spot) in manufacturing.If the fabric yarn made from wrinkle or curling yarn is loosened continually the orange skin can not appear.

Process condition shown in the test 26 is used for making 50: 50 the 2GT and the bi-component yarn of 3GT component (BC23), and the final dawn number of fixed yarn is 176.This flow process has a stretching and heat treatment (annealing) district, first fracture zone, second fracture zone and a consolidation zone, and is similar to the flow process among Fig. 8, do not use draw zone.The yarn of not being stretched feed for fiber from 4714 dawn of 24 bobbins packing compositions.Final yarn product is wound onto as on 222 the up-coiler among Figure 11.The fixed injector 83a that entwines (Figure 26 and 27) have gas enter aperture become with the yarn direct of travel 60 the degree angles.Strainer 164 is adjusted to provides enough pulling force that all elongations are all removed to fiber from feeding at roller 168 places on feeding to yarn.Yarn is stretched being heated to by fiber heater 140 under 160 ℃ the temperature, extensibility is that the 3.0X. yarn is broken and broken in section D1 and D2, be sent to not drawing-off fixed injector 83a then, make the yarn at 176 dawn, use the bobbin package at 122 places (Figure 11) again.If yarn is handled with (hot-air formula) steam heat, temperature is brought up to 100 ℃, represent again as a means of making the contraction in the long filament and curling, so this yarn CD who is about 50-60% that can be supposed to.This value a little more than in the test 25 with the tandem injector dispose the fixed and wrapped yarn made the value that can expect.If same fiber just is stretched rather than is broken, it is believed that so it can have a CD who is about 55-65%, just the latter has the feel more more suitable than continuous filament yarn bi-component yarn to this value a little more than short fiber yarn of the present invention.

The result of test 24 and 25 is wonderful, no matter be that fiber that stretched in advance or that do not stretch all can be made into the staple fibre stretch break method yarn with good runnability in drawing zone, as long as at first remove the elongation that all feed to give yarn, the fiber that stretched in advance or be stretched before long filament is broken is annealed the yarn heating then and get final product with pre-tension.Feed and to remain in the short fiber yarn of finishing basically to the elongation of fiber characteristic.

It is believed that other elastomers are the method processing that crimped fibre also can use the present invention to lecture.Other fibers can comprise combination such as the different nylon polymer or the different tissue such as the biconstitutent fibres of different polymer.The typical practice of biconstitutent fibre is core polymer such as the Lycra that a high elasticity or " soft " are arranged The elasticity elastomer, its above-mentioned " wing " portion vertical rib of conduct when spinning that is knotted non-resilient (" firmly ").Behind spinning, can make the contraction of soft core polymer surpass the contraction of hard wing polymer considerably, thereby spiral with making the complex tissue spirality, seem screw thread as screw with the elasticity of thermal excitation fiber.This fibr tissue also had " curling " at spinning with after stretching before heat treatment, similar to two component fibers.Polymer is corresponding compatible to be bonded together them and the energy cospinning.They must have the spinning viscosity of similar heat sensitivity and function for this reason.Therefore effectively to usually chemically closely similar, perhaps have some specific interaction.Common bi-component is two polyester, two nylon etc., and two composition is for example 4GT/4GT-4GO (4GT is a polybutylene terephthalate, and GO is a glyoxal) (HYTREL ) and nylon/PEBAX Homopolymers/block copolymer is right, wherein one of copolymer identical with copolymer.Ratio can have sizable variation, but generally is limited in 80/20 and 20/80, is preferably between 70/30 to 30/70.The crimped fibre that other are traditional changes short fiber yarn into as the also all available flow process of the present invention of fiber of curling with nozzle, gear crimper, stuffer box crimper etc.

Therefore method provided by the present invention can be used to break continuous filament fiber, makes discontinuous filament fiber, and these consolidated fibers are become yarn, can satisfy previously presented target and advantage fully.Though the present invention describes in conjunction with specific embodiments, obviously those skilled in the art still can make many alternative, modifications and variations to this.Therefore the present invention ought to comprise substituting in all these intention in appended claims and the broad range, modifications and variations.

Claims (10)

1. break process for one kind, go out short fiber yarn with the cause fiber production, this fiber comprises that long filament and this fiber worked continuously by feeding, and this process comprises:
In first fracture zone,, make filament breakage to increase the fiber speed in the first fracture zone length L 1 more than or equal to 2 the first speed ratio D1;
In second fracture zone that is in downstream, first fracture zone to increase the fiber speed in the second fracture zone length L 2 more than or equal to 2 the second speed ratio D2, make filament breakage, wherein the scope of the relational expression (D2-1)/(D1-1) that comprises of D2 and D1 is from 0.15 to 2.5, and the scope of the relational expression L2/L1 that L1 and L2 limit is from 0.2 to 0.6; And
Consolidation fibre in the consolidation zone in downstream, second fracture zone is to make short fiber yarn.
2. by the process of claim 1, it is characterized in that the first fracture zone length L 1 is more than or equal to 50.8 centimetres.
3. by the process of claim 2, the scope that it is characterized in that relational expression (D2-1)/(D1-1) is from 0.2 to 2.0, and the upper limit of relational expression L2/L1 is less than 0.4.
4. by the process of claim 2, it is characterized in that also being included in the interior fiber of drawing zone that the predetermined interior increase of a drawing zone length fiber speed is stretching in upstream, first fracture zone.
5. by the process of claim 4, the long filament that it is characterized in that being fed operation is not stretched or the bicomponent filament tissue that part is stretched and the cohort of pair composition long filament tissues from comprising.
6. by the process of claim 4, it is characterized in that also comprising that the fiber with adding is fed in the flow process, this flow process is in the upstream of a section of choosing from the cohort that contains first fracture zone, second fracture zone, draw zone and consolidation zone.
7. by the process of claim 6, it is characterized in that feeding and add fiber and comprise that adding fiber with first is fed in the flow process of the upstream extremity that is in first fracture zone, and second of continuous filament yarn is added fiber be fed in the flow process of upstream extremity of consolidation zone.
8. by the process of claim 2, it is characterized in that also comprising by the fiber of heating in predetermined annealed zone length the fiber in the annealed zone is annealed.
9. by the process of claim 8, it is characterized in that the long filament that is fed operation comprises the curling tissue that part is stretched and all is stretched.
10. press the process of claim 1, it is characterized in that, this process also comprises makes fiber pass through a hole, and in this hole, cause spiral fluid flow path, so as to loose filament end being assembled and loosely is wrapped in loose filament end around the core of the contiguous long filament of assembling.
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