DE60025273T2 - ROTATING TIP AND PRODUCT - Google Patents

Description

The This patent application claims priority over the provisional patent application, serial no. 60/139096, filed June 14, 1999, entitled "Tear Method and product ".

TECHNICAL FIELD OF THE INVENTION

The This invention relates generally to a fiber conversion and spinning process and in particular, methods for stretch breaking continuous filament fibers to discontinuous filament fibers and to densify them Fibers to yarns.

TECHNICAL BACKGROUND OF THE INVENTION

Spun yarns of synthetic staple fibers are made by cutting continuous filaments have been made into staple fibers, which are then the same way how cotton or wool fibers are combined to single yarn. It is also a simpler direct spinning method is applied, wherein parallel endless filaments between feed rollers and take-off rollers in a sometimes as breaking zone or as stretch cutting zone area torn and stretched be used to form a sliver of discontinuous fibers, which is then twisted into a spun yarn, such as in US-A-2721440 to New or in US-A-2784458 to Preston. Such early Procedures were because of the inherent Speed limits of a real twisting device slowly. As an alternative to real twisting, Bunting et al. in US-A-3110151 compacting staple fibers to make a yarn product using a tangling or swirling nozzle device for the Turbulence to yarn. Such a product can be faster than through Real twisted, but is in strength, cleanliness and uniformity not with conventional Spun yarns comparable. Alternatively, US-A-4080778 of Adams et al. a process whereby a 1500-1500 denier cable is heated from continuous filaments and can be stretched and then torn in a single zone and stretched and through a perforated draw roll and a suction nozzle for maintaining the parallel flow of fluid and fiber the roll nip or intake roll nip at high speed exit. The discontinuous, uncompacted fibers become then in a vortex nozzle compacted from a type disclosed in Bunting to a yarn of 50-300 to manufacture. Static charges are in the tear and draw zone removed in order to minimize the spreading of the fibers. Become anti-static devices Also disposed adjacent to the roller pairs, which are the filaments through the process. Approximately 1.5-20% the one in the break zone produced discontinuous filaments are longer than 76 cm. The yarn axis must during the to be vertical throughout the process. The resulting product is a compacted yarn of excellent strength, in general is higher as with ring-spun yarns, the yarn without thickening and is clean.

Gilhaus US-A-4,924,556 teaches a plurality of break zones to progressively reduce the length of discontinuous filaments for coarse cables constructed by combining a plurality of lightweight cables, via tie bars and guide elements. In this way, deformations of less than 4.5 with light feed cables can be performed, and production capacity remains high. The combined cables are drawn in a deformation and heating zone (zone I) at a horizontal level without tearing and then successively passed through one or more ever shorter break zones (zones II-V) horizontally arranged at a different level by footprint to save. The break zones may include one or more "temporary" break zones in which the fibers are progressively shortened and one or more break zones defining the average filament length and the fiber length (% CV) spread. The formed sliver may be processed in a braiding device (to facilitate later handling), heat treated and collected in a container. It is expected that the sliver will be further processed, such as in a spinning machine, to produce fine yarns. The process processes feed cables of 3.0 denier per filament and 110000-220000 denier, and in a belt of width greater than 270 mm in the draw and pull zones. At the in 1 The example shown is a first preliminary break zone, Zone II, at least 500 mm long, and the filament lengths resulting from this zone have "approximately normal" filament lengths between a few millimeters and the length of zone II. The length of Zone II is an optimization between a longer length, which reduces the tearing forces, and a smaller length, which avoids flake cracks and improves the operating conditions. There is a second preliminary break zone, Zone III, which is at least 200 mm and less than 1000 mm long and "considerably shorter" than Zone II. Then there is a first break zone, zone IV, which defines the average fiber length and appears shorter than zone III, and a second break zone, zone V, which removes too long fibers, determines the fiber length dispersion (characterized by% CV), and shorter than Zone IV appears. In zone V, the "fracture deformations" (elongation at break) (which are assumed as velocity ratios at least twice as large as in zone IV.

One horizontal series or continuous process for producing a Bündelgarns from a fiber cable is disclosed by Minorikawa et al. in US-A-4667463 taught. The method involves stretching the cable in one extended Range of narrow width, stretch cutting the cable and performing a supplementary Stretch cutting step and a Garnbildungschritts to the stretch-cut Fibers. The length the zone in the supplementary Stretch cutting step is about 0.4 to 0.9 times the length of the stretch-cutting zone, and the stretch ratio for the supplementary Stretch cutting step is at least 2.5 ×. The stretching is preferably done in two stages to a draw ratio of 90-99 the maximum stretch ratio to reach, and the stretched fiber is then heat-treated. The yarn-forming step uses a nozzle system for compacting the Fibers by creating sheath fibers around the fiber core and Winding the sheath fibers on the core fibers. Occasionally Riemchenbänder in the supplementary stretch cutting zone and the yarn-forming zone is used to control the edge fibers. According to the description in US-A-4356690 to Minorikawa et al. is the product by the Fact characterizes that more than about 15% of the filaments in the yarn have a filament length of less than 0.5 times the mean filament length of the Yarns and more than about 15% of the filaments in the yarn a filament length of more than 1.5 times the average filament length of the yarn. In the illustrated examples is the maximum exit velocity of the process, with the yarns from 174 to 532 denier (cotton number 30.5 to 10), 200 m / min (Example 6), the Most examples are operated at about 100 m / min.

at that of Adams et al. produced products there is a problem insofar than the 1.5-20% discontinuous filaments greater than 76 cm in length, the in the only breaking zone caused problems in further processing (in first line winding on rollers), especially if one is not vertical process alignment chosen becomes. A problem with long filaments in the Adams product is also that it the number of available ones Thread ends bounded out of the yarn and the yarn one give a comfortable grip and good appearance for textile applications.

Of the Case of horizontal orientation according to Gilhaus is effortless only on the processing big Cable applicable, where it is assumed that the large number of threads to a good Friction between discontinuous filaments within the bundle contributes, so that the integrity of the bundle without Difficulty can be maintained. In the case of Adams worry the small thread counts in the uncompacted discontinuous Yarn for low friction cohesion. It is assumed that a vertical orientation is required to be sensitive to the Yarn attacking, gravity-related lateral forces to eliminate before the Yarn is solidified by the compaction.

Adams beats before, the entire stretch tearing in one zone and any stretching of the yarn in the same zone perform. Such a multi-purpose zone makes independent optimization of finished yarn parameters difficult or impossible.

Minorikawa et al. may have a problem in the control of discontinuous filaments, such as the use of strappy bands shows. This lack of control and the use of Riemchenbändern can the Speed of this method to those disclosed in its examples Speed limit, which with 200 m / min too slow for the large-scale Production of a single fine-yarn line is.

It there is a need for an improved process for the production of stretched stretch yarn, wherein the operating parameters independent can be optimized the process does not focus on operation in vertical orientation limited and there are no too long filaments that are present from the filament bundle Separate and wind up in the processing plant and the thread count in the yarn can limit. There is a need for a process that is stable and high speed of more than 250 m / min can work to make a yarn line all at once directly from cable economically attractive.

SUMMARY THE INVENTION

Applicants have developed a process that produces fine yarn from discontinuous filaments having filament lengths shorter than 64 cm (25 inches), producing a large number of thread ends per inch, from continuous filament feed yarn. The new process operates at speeds that make production of single yarns commercially viable. The production speeds are much higher than those of ring-spun staple yarns which traditionally have a high number of thread ends per inch. The method allows operation in either vertical or horizontal orientation without loss of running ability. The process is adaptable to a variety of continuous filament polymers and to the blending of dissimilar continuous filament yarns. In preferred embodiments, the process utilizes at least two break zones to achieve the preferred filament lengths in the final yarn product having an average filament length greater than 15.24 cm (6.0 inches), and the speed ratio D1 of the first break zone and the speed ratio D2 of the second Break zone should be at least 2.0. In addition, a relationship L2 / L1 between the length L2 of the second break zone and the length L1 of the first break zone is limited to a range of 0.2 to 0.6 in order to achieve the desired total filament lengths, the desired length distribution, and good system performance , The break zones are followed by a densification zone to densify the discontinuous filaments in the yarn and to entangle the filaments by various means to maintain yarn uniformity. The method includes improvements to systems with one or more break zones.

A feature of the new process is based on the view that it is important to provide for some "double clamped" filaments throughout the tearing and drawing process. Double clamped filaments are those that are long enough to span the space between two groups of rolls for each tear and draw zone. Double clamped filaments provide some support for the other filaments, thus providing good bond of the filament bundle in each zone which promotes runnability, especially in the production of fine filaments with few filaments. It is believed that the use of low speed ratios in the break zones results in longer filaments that can serve as double clamped filaments, but this requires more break zones to achieve a high overall speed ratio to improve productivity. It also results in the need for more break zones to reduce filament lengths to a low level desirable for making yarns having a large number of thread ends. It is believed that the above thread ends give the yarn a better grip or a better "grip". Applicants have found that there is a preferred method of optimizing machine runnability in making fine yarns with shorter fibers to optimize yarn ends per inch. To improve productivity, the overall speed ratio of the process must remain high, and the increase in speed ratio, while maximizing runnability, must involve at least two break zones, requiring maintenance of a certain minimum amount of double clamped filaments in each zone. Applicants have found that certain process parameters must be carefully controlled to produce a desired product. The relationship between the speed ratio D1 ≥ 2.0 of the first break zone and the speed ratio D2 ≥ 2.0 of the second break zone should also preferably satisfy the following condition: (D2 - 1) / (D1 - 1) ≥ 0.15

More preferably, the relationship should satisfy the following condition: 2.5 ≥ (D2 - 1) / (D1 - 1) ≥ 0.15.

In one more preferred embodiment is also the zone length the second zone is less than or equal to 0.4 times the first zone length.

In a further preferred embodiment will be a separate zone in the first place for stretching already cracked filaments provided without further tearing.

In further embodiments will also a stretch zone for stretching the fiber without stretch tearing the Filaments used, in a stretching zone that precedes the break zones and which can stretch the fiber with or without heat. In addition, will used an annealing zone, if desired, to the fibers too heat and control product features, such as B. the shrinkage. An annealing zone is especially common Part of the draw zone, but may be at different points in the process be used.

• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge, avg, der Filamente größer als 15,24 cm (6 Zoll) ist und die Faser eine Filamentlängenverteilung aufweist, die durch die Tatsache gekennzeichnet ist, daß 5% bis weniger als 15% der Filamente eine Länge aufweisen, die größer als 1,5 avg ist.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit der Garns aufrechtzuerhalten, wobei die mittlere Länge der Filamente größer als 15,24 cm (6 Zoll) ist, und wobei die Faser kontinuierliche Filamente enthält, die mit den diskontinuierlichen Filamenten in Längsrichtung des Garns verwirbelt werden, wobei die kontinuierlichen Filamente eine Reißdehnung von weniger als 10% aufweisen.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einleitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge der Filamente größer als 15,24 cm (6 Zoll) ist, und wobei die Faser kontinuierliche Filamente enthält, die mit den diskontinuierlichen Filamenten in Längsrichtung des Garns verwirbelt werden, wobei die kontinuierlichen Filamente elastische Filamente mit einer Reißdehnung von mehr als etwa 100% und einer elastischen Erholung von mindestens 30% nach einer Dehnung um 50% aufweisen.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge der Filamente größer als 15,24 cm (6 Zoll) ist, wobei mindestens 1% der diskontinuierlichen Filamente in dem Garn nach Denier eine Faser mit einem Reibungskoeffizienten zwischen Filamenten von 0,1 oder weniger aufweisen. Vorzugsweise ist die Komponente mit niedriger Reibung ein Fluorpolymer.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge, avg, der Filamente größer als 15,24 cm (6 Zoll) ist und die Faser eine Filamentlängenverteilung aufweist, die durch die Tatsache gekennzeichnet ist, daß 5% bis weniger als 15% der Filamente eine Länge von mehr als 1,5 avg aufweisen, und wobei der Filamentquerschnitt eine Breite und mehrere dicke Abschnitte aufweist, die innerhalb der Filamentbreite durch dünne Abschnitte verbunden sind, und wobei die dünnen Abschnitte an den Enden der diskontinuierlichen Filamente durchtrennt werden, so daß die dicken Abschnitte über eine Länge von mindestens etwa 3 Filamentbreiten aufgetrennt werden, um dadurch gespaltene Filamentenden zu formen.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge, avg, der Filamente größer als 15,24 cm (6 Zoll) ist und die Faser eine Filamentlängenverteilung aufweist, die durch die Tatsache gekennzeichnet ist, daß 5% bis weniger als 15% der Filamente eine Länge von mehr als 1,5 avg aufweisen, und wobei die Faser in dem Garn zwei Fasern aufweist, die optisch ausgeprägte, mit dem bloßem Auge erkennbare Unterschiede aufweisen. Vorzugsweise sind die Unterschiede ein Farbunterschied, wobei die Farben der Fasern neutrale Farben mit einer Helligkeit von mehr als 90% ausschließen, und wobei die Faserfarben eine Farbdifferenz von mindestens 2,0 CIELAB-Einheiten aufweisen, wobei Helligkeit und Farbdifferenz nach dem Standard E-284 des ASTM-Committee E12 gemessen werden, um ein mehrfarbiges Garn zu bilden.
• – ein Garn mit verdichteter Chemiefaser aus diskontinuierlichen Filamenten unterschiedlicher Länge, wobei die Filamente in Längsrichtung des Garns verwirbelt werden, um die Einheitlichkeit des Garns aufrechtzuerhalten, wobei die mittlere Länge, avg, der Filamente größer als 15,24 cm (6 Zoll) ist, und wobei mindestens 1% der diskontinuierlichen Filamente in dem Garn nach Denier eine Faser aufweisen, die Filamente mit einer latenten Elastizität von 30% oder mehr aufweist. Vorzugsweise ist die Faser ein Bikomponentengarn mit einer ersten Komponente aus 2GT-Polyester und einer zweiten Komponente aus 3GT-Polyester. Für die Herstellung einiger von den gerade diskutierten Produkten werden unterschiedliche Verfahren offenbart. Andere Verfahren werden für die Umrüstung einer herkömmlichen Stapelfaserspinnmaschine in eine Maschine für die Herstellung von Zulauffaser für eine Streckreißmaschine offenbart. Die Verfahren beinhalten die Durchführung des Betriebs der Spinnmaschine, das Spinnen von mindestens 500 Fasern in einer Spinnposition zur gleichzeitigen Herstellung einer Vielzahl von Produkten mit einer Einzellosgröße von etwa 9,07 bis 90,7 kg (20 bis 200 lb), die in einem Behälter aufgefangen werden, wobei die Losgröße kleiner als ein Los des einzigen groben Kabelprodukts ist; und die Bereitstellung mindestens einer Spinnposition mit einer Einrichtung zum Auffangen von Kabel von der mindestens einen Spinnposition in einem Behälter bei der Herstellung eines feinen Kabelprodukts.

The process produces novel products by providing an opportunity to incorporate various fibers into the process in a manner not previously disclosed to produce a large collection of stretch yarns. For example, in a variety of different zones used in the process, additional fibers may be introduced at various points in the process to achieve unusual and novel results. Typical of such products are those which are continuous filament yarns are intermixed with discontinuous filament yarns by introducing the continuous filament yarns at one point downstream from the tear and draw zones and from the one or more densification zones. Other products use polymer materials having properties that are not intended for use in a tearing process, especially in a process of applicants with extraordinary operations. These products include the following:

• A yarn of compacted chemical fiber of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain the uniformity of the yarn, the average length, avg, of the filaments being greater than 15,24 cm (6 inches) and the fiber has a filament length distribution characterized by the fact that 5% to less than 15% of the filaments have a length greater than 1.5 avg.
• A denier-fiber-twisted yarn of discontinuous filaments of different lengths, wherein the filaments are entangled in the longitudinal direction of the yarn to maintain the uniformity of the yarns, the average length of the filaments being greater than 15,24 cm (6 inches); Fiber contains continuous filaments that are entangled with the discontinuous filaments in the longitudinal direction of the yarn, wherein the continuous filaments have an elongation at break of less than 10%.
• A denier-fiber-twisted yarn of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain the ease of initiation of the yarn, the average length of the filaments being greater than 15,24 cm (6 inches); Fiber contains continuous filaments that are entangled with the discontinuous filaments in the longitudinal direction of the yarn, wherein the continuous filaments have elastic filaments with an elongation at break of more than about 100% and an elastic recovery of at least 30% after an elongation of 50%.
• A denier-fiber-twisted yarn of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain yarn uniformity, the average length of the filaments being greater than 15.24 cm (6 inches), with at least 1 % of the discontinuous filaments in the denier yarn have a fiber having a friction coefficient between filaments of 0.1 or less. Preferably, the low friction component is a fluoropolymer.
• A yarn of compacted chemical fiber of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain the uniformity of the yarn, the average length, avg, of the filaments being greater than 15,24 cm (6 inches) and the fiber has a filament length distribution characterized by the fact that 5% to less than 15% of the filaments have a length greater than 1.5 avg, and wherein the filament cross section has a width and a plurality of thick portions within the filament width are joined by thin sections, and wherein the thin sections at the ends of the discontinuous filaments are severed so that the thick sections are separated over a length of at least about 3 filament widths to thereby form split filament ends.
• A yarn of compacted chemical fiber of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain the uniformity of the yarn, the average length, avg, of the filaments being greater than 15,24 cm (6 inches) and the fiber has a filament length distribution characterized by the fact that from 5% to less than 15% of the filaments are greater than 1.5 avg in length, and wherein the fiber in the yarn has two fibers which are optically distinct show recognizable differences to the naked eye. Preferably, the differences are a color difference, wherein the colors of the fibers preclude neutral colors with a brightness of more than 90%, and wherein the fiber colors have a color difference of at least 2.0 CIELAB units, wherein brightness and color difference according to the standard E-284 of the ASTM Committee E12 to form a multi-colored yarn.
• A yarn of compacted chemical fiber of discontinuous filaments of different lengths, the filaments being entangled in the longitudinal direction of the yarn to maintain the uniformity of the yarn, the average length, avg, of the filaments being greater than 15,24 cm (6 inches), and wherein at least 1% of the discontinuous filaments in the denier yarn have a fiber having filaments with a latent elasticity of 30% or more. Preferably, the fiber is a bicomponent yarn having a first component of 2GT polyester and a second component of 3GT polyester. Different processes are disclosed for the preparation of some of the products just discussed. Other methods are disclosed for converting a conventional staple fiber spinning machine to a machine for producing inlet fiber for a stretch ripper. The methods include performing the operation of the spinning machine, spinning at least 500 fibers in a spinning position to simultaneously produce a plurality of products having a single lot size of about 9.07 to 90.7 kg (20 to 200 lb) contained in a container to be collected, the lot size being less than one lot of the single coarse cable product; and the provision of at least one spinning position comprising means for collecting cables from the at least one spinning position in a container in the manufacture of a fine cable product.

• Raffen der losen Filamentenden in der Reißzone und angrenzend an die Austrittsklemmwalzen und Führen der Filamentenden zum Faserkern hin, so daß die losen Enden in allen Richtungen um den Kern herum auf einen Abstand von der Kernmitte beschränkt werden, der nicht größer ist als der Abstand der Kernmitte vom jeweiligen Ende der Austrittsklemmwalzen für die Reißzone, um das Aufwickeln der losen Enden auf die Austrittsklemmwalzen zu minimieren.
• – Gefaltete Anordnung der Faserwege durch die Funktionszonen in einem Streckreißverfahren„ so daß, wenn ein Wegvektor in einer ersten Funktionszone Ende an Ende mit einem Wegvektor in einer nächstfolgenden Funktionszone angeordnet wird, ein eingeschlossener Winkel zwischen 45° und 180° definiert wird, woraus sich eine kompakte Aufstellungsfläche für das Verfahren ergibt.
• – Anordnen des Weges der diskontinuierlichen Filamentfaser am Ausgang der ersten Reißzone und am Eingang und Ausgang der zweiten Reißzone, um die Faser zunächst mit einer elektrisch leitenden Klemmwalze in Kontakt zu bringen, bevor sie mit einer elektrisch nichtleitenden Klemmwalze in Kontakt gebracht wird, um die Faser von einer elektrisch nichtleitenden Klemmwalze nur so zu trennen, daß die Faser zuerst von der elektrisch nichtleitenden Klemmwalze getrennt wird, bevor sie von einer elektrisch leitenden Klemmwalze getrennt wird, um dadurch eine statische Aufladung in der Faser bei ihrem Durchlauf durch die Klemmwalzen zu minimieren.

Various improvements are disclosed in conventional stretch breaking processes, including:

• Gathering the loose filament ends in the break zone and adjacent to the exit nips and guiding the ends of the filaments towards the fiber core such that the loose ends are confined in all directions about the core to a distance from the core center that is not greater than the pitch of the core center from the respective end of the exit pinch rolls for the break zone to minimize the winding of the loose ends onto the exit pinch rolls.
• - Folded arrangement of the fiber paths through the functional zones in a stretch breaking process "so that when a path vector is arranged in a first function zone end to end with a path vector in a next functional zone, an included angle between 45 ° and 180 ° is defined, resulting in a compact installation surface for the process results.
• Arranging the path of the discontinuous filament fiber at the exit of the first break zone and at the entrance and exit of the second break zone to first contact the fiber with an electrically conductive pinch roller before being brought into contact with an electrically non-conductive pinch roll around the fiber only to be separated from an electrically non-conductive pinch roll such that the fiber is first separated from the electrically non-conductive pinch roll before being separated from an electrically conductive pinch roll to thereby minimize static charge in the fiber as it passes through the pinch rolls.

Further Variants of the process and the products produced thereby are for the Specialist in fiber processing from the description below seen.

DESCRIPTION THE DRAWINGS

Further Features of the present invention will become apparent in the course of the following Description and with reference to the drawings. Showing:

1 a schematic side view of a production line, which has a first and a second breaking zone and a compression zone;

1A an enlarged view of a roll group where the fiber path is an "omega" path, which is particularly useful in a high-strength fiber or a low-friction fiber;

2 a schematic perspective view of filament ends and double clamped filaments in a fiber, which is torn between two groups of rolls;

3 a graph of fiber ratio of double clamped fibers versus total velocity ratio for two cases of fiber tear tears using a simulation model;

4 FIG. 4 is a graph of a fiber ratio of double clamped fibers versus speed ratio for a single case of two break zones for stretch pulp fibers using a simulation model; FIG.

5 a sensitivity diagram of the information from 4 taking into account changes in fiber tear propagation e _b ;

6 a sensitivity diagram of the information from 4 taking into account changes in the length of break zone 2 compared to the length of zone 1;

7 a sensitivity diagram of the information from 4 taking into account changes in the overall speed ratio for the two break zones;

8th a schematic side view of a production line, which has a draw zone, a first and a second break zone and a compression zone, wherein the draw zone can also function as an annealing zone;

9 a schematic side view of a production line, which has a draw zone, a first and a second break zone, a draw zone and a compression zone.

10 the curves of 4 with the left vertical axis stretched and a right vertical axis added to the curves of 4 to compare with some real test data;

10A a data plot of a designed health test for different values of D1 and D2 to capture optimal data for the graph of 10 ,

11 a schematic side view of a machine for practicing the method according to the 1 . 8th and 9 and its variants;

12 a perspective view of a swirl nozzle according to 11 for swirling loose filaments around the fiber;

13 a schematic representation of a thread laying device (Piddling) for depositing (Piddlen) of feed fiber through a fiber distribution rotor in a vibrating container;

14 a sectional view of the rotor of 13 ;

15 a diagram of the filament length distribution for a real yarn test and a simulation of this test;

16 and 17 a simulation of two comparative examples using only a break zone and the resulting fiber distribution which is outside the limits of the invention;

18 and 19 Simulations of other operating conditions and the resulting fiber distribution, which is within the limits of the invention;

20 the process scheme of 9 wherein an additional feed fiber is introduced at the feed end of the compression zone;

21 the process scheme of 9 wherein an additional feed fiber is introduced at the feed end of the first break zone;

22 the process scheme of 9 wherein a first additional feed fiber is introduced at the feed end of the first break zone and a second additional feed fiber is introduced at the feed end of the compression zone;

23 a schematic side view of the production line of 9 having an annealing zone behind the compression zone;

24 a photomicrograph of a ruptured filament with split ends;

25 a cross section of the filament of 24 ;

26 a perspective view of a Verwirbelungsdüse for densification of the fiber;

27 a section 26-26 through the nozzle of 26 ;

28 a pneumatic torsion member for compacting the fiber, wherein the left half of the drawing is a sectional view taken along the fiber path and the right half is a plan view;

29 an isometric view of a staple fiber spinning machine for the production of coarse cable product, which is fed to a conventional stacking yarn method;

30 an isometric view of a staple fiber spinning machine that has been modified to provide both fine and coarse cable product;

31 an isometric view of a staple fiber spinning machine that has been modified to fei to deliver a cable product from single positions, which is fed to a stretched-stretch yarn process;

32 a schematic representation of a production line with a folded path, the installation area saves;

33A , B and C are schematic representations of function zone path vectors for the zones of FIG 32 ;

34A and 34B Sectional views of a trough that collects loose filament ends towards the fiber core before the fiber passes through a pinch roller;

35 a typical diagram of the yarn strength as a function of the distance between two nozzles of a compacting device for different average filament lengths.

The While the present invention is in conjunction with a preferred embodiment of the invention, but it is understood that not it is intended to limit the invention to this embodiment. in the The opposite is intended, all alternatives, modifications and equivalents include, the under circumstances are included in the spirit and scope of the invention, as by the attached claims Are defined.

DETAILED DESCRIPTION

Referring to the drawings 1 a schematic of a preferred stretch-breaking process for a fiber 30 to form a yarn 32 using at least a first break zone 34 and a second break zone 36 and a compression zone 38 , The fiber 30 containing several fibers 30a . 30b and 30c can be the method at a feed end 40 of the process by a first group of rolls 42 fed to the rollers 44 . 46 and 48 having. The roller 46 is driven at a predetermined speed by a conventional motor-gear unit and a controller (not shown), and the rollers 44 and 48 be through their contact with the roller 46 driven. The fiber 30 becomes a second group of rolls 50 fed, creating the first breaking zone 34 between the roller groups 42 and 50 is defined. The roll group 50 has a roller 52 , a roller 54 and a roller 56 on. The roller 54 is driven at a predetermined speed by a conventional motor-gear unit and a controller (not shown), and the rollers 52 and 56 be through their contact with the roller 54 driven. The first break zone 34 has a length L1 between the nip of the roller 46 and the roller 48 who is on the line 58 between their centers, and the nip of the rollers 52 and 54 who is on the line 60 between their centers. The fiber velocity will be within the first break zone 34 increased by passing the fiber through the roller group 42 at a first speed S1 and through the roller group 50 is driven at a second speed S2, which is higher than the speed S1. By comparing the fiber velocities at the two roll groups 42 and 50 a first speed ratio D1 = S2 / S1 is defined. No slippage should occur between the roller and the fiber, and therefore, the fiber speed and the roller surface speed are at the driven roller 46 equal to, and the fiber speed and the roller surface speed at the driven roller 54 are equal. Increase the fiber velocity within the first break zone 34 causes filaments in the fiber which are longer than the length L1 to be stretched until the elongation at break of the fiber is exceeded and the filaments clamped by both groups of rolls are torn. In the first zone, for stretch breaking of the filaments, the speed ratio D1 should be such that the maximum elongation of the filaments exceeds the elongation at break of the fiber, which is a known condition for fiber breakage. If the fiber fed to the process is a fiber consisting entirely of continuous filaments and the above conditions for stretch breaking of filaments are met, then all the filaments in the first break zone are torn. After stretch breaking of the continuous filaments, the now discontinuous filament fiber can also be in the first break zone 34 be stretched to reduce the denier of the fiber as the speed of the fiber increases until it reaches the speed S2 of the roll group 50 reached.

The fiber 30 becomes a third group of rolls 62 fed, creating the second breaking zone 36 between the roller groups 50 and 62 is defined. The roll group 62 shows the roller 64 , the roller 66 and the roller 68 on. The roller 66 is driven at a predetermined speed by a conventional motor-gear unit and a controller (not shown), and the rollers 64 and 68 be through their contact with the roller 66 driven. The second break zone 36 has a length L2 between the nip of the roller 54 and the roller 56 who is on the line 70 between their centers, and the nip the rollers 64 and 66 who is on the line 72 between their centers. The fiber velocity becomes within the second break zone 36 increased by passing the fiber through the roller group 50 at a second speed S2 and through the roller group 62 is driven at a third speed S3, which is higher than the speed S2. By comparing the fiber velocities at the two roll groups 50 and 62 a speed ratio D2 = S3 / S2 is defined. There should be no slippage between the roller and the fiber; therefore, the fiber speed and the roller surface speed are at the driven pulley 54 equal to, and the fiber speed and roller surface speed on the driven roller 66 are equal. The increase in fiber velocity within the second break zone 36 causes most of the filaments in the fiber, which are longer than the length L2, to be stretched until the elongation at break of the fiber is exceeded and most of the filaments clamped by both sets of rolls (double clamped filaments) stretch break. In the second zone, for stretch breaking of the filaments, the speed ratio D2 should be such that the maximum elongation of the double clamped filaments exceeds the elongation at break of the fiber, which is a known condition for stretch breaking of discontinuous filament fibers. The fiber with discontinuous filaments can also be in the second breaking zone 36 be stretched to reduce the denier of the fiber while the speed of the fiber continues to increase until it reaches the speed S3 of the roll group 62 reached.

The fiber 30 becomes a fourth roller group 74 fed, causing the compression zone 38 between the roller groups 62 and 74 is defined. The roll group 74 has a roller 76 and a roller 78 on. The roller 76 is driven at a predetermined speed by a conventional motor-gear unit and a controller (not shown), and the roller 78 gets through her contact with the roller 76 driven. The compression zone 38 has a length L3 between the nip of the roller 66 and the roller 68 who is on the line 80 between their centers, and the nip of the rollers 76 and 78 who is on the line 82 between their centers. The compression zone contains certain compression devices, such. B. one between the roller groups 62 and 74 illustrated swirl nozzle 83 , The fiber velocity can be within the compression zone 38 be easily reduced by passing the fiber through the roll group 62 is driven at the third speed S3 and through the roller group 74 is driven at a fourth, lower speed S4. By comparing the fiber velocities at the two roll groups 62 and 74 a speed ratio D3 = S4 / S3 is defined. There should be no slippage between the roller and the fiber; therefore, the fiber speed and roller surface speed are at the driven roller 66 equal to, and the fiber speed and the roller surface speed at the driven roller 76 are equal. The swirl nozzle joins the filaments by entangling them together to form a staple yarn and, in forming the staple yarn, can easily shorten the filament length, thus explaining the reduced speed in that particular compaction zone. In certain cases, it may be desirable to control the fiber velocity within the compression zone 38 increase by passing the fiber through the roller group 62 at the third speed S3 and through the roller group 74 is driven at a fourth speed S4 which is higher than the speed S3. In this case, would be within the compression zone 38 a certain stretching occur as the fiber speed further increases until it reaches the speed S4 of the roll group 74 reached.

How to continue 1 recognizable, are the groups of rolls 42 . 50 and 62 shown as three groups of rollers, wherein the fiber passes through the roller groups substantially "straight" and thereby wound up a little on the rollers. This is often a simple, effective way to provide good fiber chucking and to obtain a simple fiber threading path for the process. It is believed that it is important to regulate the static charge on the fibers while in the break zones 34 and 36 be torn. From the fiber surface usually go free fiber ends resulting from the tearing of the filaments, and are repelled by static forces, while the filaments slide on each other. These protruding, statically charged free ends wrap easily on the pinch rollers, especially in the roll groups 50 and 62 , causing machine downtime. It is believed that it is useful to contact the fibers with an electrically conductive roller surface to dissipate the static charge. This can be done by performing at least one of the pinch rolls clamping the uncompressed discontinuous fiber with a metallic conductive surface, e.g. B. the rollers 44 . 48 . 52 . 56 . 64 and 68 , The roller 76 may also have a conductive surface, but this is not as important as the free ends are compressed with the fiber core as they pass through this nip. Likewise, the roller needs 44 may not be metallic because at this point the fiber is still a bundle of continuous filaments and there are no free ends. At the roller 48 because of in the breaking zone 34 take place dynamic dynamic tearing process some free ends, so that a roller 48 with conductive surface in front can be part. In the case of the roll group 50 show the rollers 52 and 56 Metallic surfaces, which with a non-conductive, elastic elastomer surface on the roller 54 are in contact. When contacting with a roller group, such as. B. 50 , it is also important to arrange the path of the fiber with discontinuous filaments at the entrance and exit of the roller group so that the fiber is first brought into contact with an electrically conductive pinch roller before being brought into contact with a non-conductive pinch roller and that the Fiber is only separated from a non-conductive pinch roll by first separating the fiber from the electrically non-conductive pinch roll before separating it from an electrically conductive pinch roll to thereby minimize static charge in the fiber as it passes through the pinch rolls. In other words, the first surface with which the fiber entering a pinch roller group should come into contact should be a conductive surface, and the last surface with which the fiber emerging from a pinch roller group should be in contact should be a conductive surface. If the fiber instead from the elastomer surface of the roller 54 after they replaced the metal roller 56 In the separation of fiber and elastomer, a static charge would be generated which would not readily be dissipated since the fiber itself is electrically nonconductive. Accordingly, the rollers 52 and 56 obliquely around the center of the roller 54 arranged around so that a wrap angle 51 of about 5 ° or more on the roller 52 occurs before the fiber comes into contact with the roller 54 comes while a wrap angle 53 of about 5 ° or more on the roller 56 occurs after the fiber is off the roller 54 separates. This situation is repeated for the roller group 62 ,

There many roll wraps apparently at the exit of the fiber from a Clamping gap between rollers occur, it is believed that it also It is important to put the fiber in contact with a rigid pinch roller hold, such. As a metallic pinch roller, since the fiber has a regardless of whether leaves the elastic elastomer clamping roller Rollers with a rigid or elastic surface are conductive or non-conductive. On This way the fiber can, if easily in the elastic surface of the Elastomer roller is embedded, "detached" from the elastic surface by the rigid surface the opposite Pinch roller follows while The fiber winds a little bit on the rigid roller. The above discussed wrap around the rolls with metal surface would this To serve a purpose. It is believed that by doing so the winding formation on rollers is minimized. When the rigid roller surface is electrically is conductive, this is another advantage as mentioned above.

1A shows with reference to the roll group 42 Another way to thread into the roll groups, which is referred to as "omega" loop. In this alternative, the fiber is under the roller 44 instead of being introduced and then around the roller 44 , the roller 46 wrapped and under the roller 48 carried out. This increases the surface contact between the fiber and the rollers 44 . 46 and 48 considerably. This is a viable process if the fiber requires good frictional engagement with the set of rolls to avoid slippage of the fiber across the set of rolls. Conditions where this is required may be present when the fiber is a high strength fiber and a high tearing force must be developed through the roller groups, or when the fiber has a very low coefficient of friction between filaments in the fiber and between the fiber and roller surfaces. Fluoropolymer fiber, whose static coefficient of friction between filaments is less than or equal to about 0.1, would be one such fiber that, when processed by stretch breaking, would benefit from an "omega" sling. The roller has this omega loop 48 a conductive surface and has a large wrap angle 55 of more than 90 ° with the fiber after moving from the roller 46 has separated, which has a non-conductive elastomer surface. This effectively dissipates the static charge that results from the separation of the fiber from the elastomer surface, as discussed above.

Everywhere in In industry, the term "fiber" is attributed a variety of meanings. For purposes In the present specification, the term "fiber" means an elongated one textile material with one or more ends or bundles same or different material with multiple filaments, which may be discontinuous or continuous and are uncompressed, which gives considerable mobility between the filaments remains. Filaments are single units of continuous or discontinuous (i.e., finite) material. The term "yarn" or "staple fiber yarn" means an elongated one textile material comprising a compacted fiber, the discontinuous one Contains filaments the compacted fiber has considerable tensile strength and uniformity in the longitudinal direction of Has yarn and filament mobility present, but limited is. Continuous filaments can also be present in the yarn or Stapelfasergarn.

The feed fiber for the process described above may come from a fiber spool or may come from a fiber-laid container from which the fiber can be freely removed, as discussed further below. The compacted yarn may be used for transport to another process or to Ver sand wound into a bobbin or stored in a container or forwarded to other machine elements for further processing.

The Terms "breaking zone" and "tearing the Filaments "relate on the speed increase of the Fiber having continuous or discontinuous filaments, in a zone for the main purpose is to tear the fibers so that more than 20% and preferably More than 40% of the filaments are torn. If the breaking zone is continuous Filaments or discontinuous filaments are fed, the longer are considered the breaking zone, then 100% of the filaments are torn. "Breaking zone" and "tearing the Filaments "can also cutting or weakening all or part of the continuous or long discontinuous Include filaments such as B. in a cutting converter device or a Reißstabvorrichtung (as described in US-A-2721440 to New or in US-A-4547933 to Lauterbach), whereby the tensile forces acting on the pinch rollers are reduced and the contingency the tear position the filaments in the fiber is somewhat controlled.

"First break zone" and "second break zone" mean two separate ones Break zones, the second in moving the fiber through the two breaking zones behind the first occurs. It is envisaged that the second break zone not the next after the first break zone needs to be and the first break zone not the first zone in a process needs to be. The entering into the first breaking zone Fiber can be a fiber with continuous filaments, a fiber with long discontinuous filaments that are in the first breaking zone to tear, or a combination of a fiber with continuous and discontinuous Be filaments. It is envisaged that the compression a connection the filaments in the fiber by any compaction means includes, such as B. a single fluid nozzle, several fluid nozzles, a real twisting device, a self-winding device, a binder applicator or the like, a rewinding device etc.

In order to achieve practical stretch breakage of the fiber in a single break zone, it is known that the breaking tension of a fiber decreases with increasing speed ratio for stretch breaking of the fibers. At a very low speed ratio of less than two, the stress increases rapidly, and it is believed that as it increases, the stress densifies the fiber to increase friction between adjacent filaments and make tearing of individual filaments harder. As a result, the stress increases and becomes very uneven, resulting in operability problems and stretch tearing of the entire fiber rather than the statistical stretch tearing of single filaments. For this reason, it is desired to operate each break zone at a speed ratio of at least 2.0. This is also advantageous for product throughput. In addition, it is desired to provide a large number of filament ends in the compacted yarn. This can be done by making the zone length of the second break zone significantly shorter than the first break zone to shorten the filaments in the fiber and to produce more filament ends per inch of dense yarn. Preferably, the length of the second break zone L2 is less than or equal to 0.6 times the first zone length L1. In a more preferred embodiment, it is desired that the second length L2 be less than or equal to 0.4 times the first length L1. There is a practical limit to the minimum length of the second break zone where almost all fiber filaments coming from the first zone are torn. This is undesirable because it causes the tension to increase to a high level and, as is known, the tearing forces decrease with decreasing length of the zone. A practical lower limit for L2 for break zone 2 is L2 ≥ 0.2 L1. The natural consequence of this logic is that it is desirable to design the first zone considerably longer than the second, since it is known that the breaking tension of filaments decreases in long zones. It is considered important that L1 be large in comparison to any given generated (ie, set by the second break zone) average filament length to reduce the required tearing forces and expose a larger filament length to tearing forces, thus exposing more filament weaknesses to tearing. An average filament length greater than 15.24 cm (6.0 inches) is considered desirable, which, after experience with break zones, means that L2 is approximately greater than about twice the mean filament length or greater than 30.48 cm (Fig. 0 inch), which means that L1 at the maximum L2 / L1 ratio desired of 0.6 is greater than 1.67 x 30.48 cm or 50.8 cm (20.0 inches). There is a relationship between the first and second break zones which ensures that the method has good operability and the yarn has certain desirable filament length and distribution characteristics and provides for a greater frequency of filament ends in a torn yarn. Good operability also provides the possibility of stable, high-speed operation at exit speeds greater than 182.88-228.6 m / min (200-250 yards / min), and more particularly, greater than about 457.2 m / min (500 Yard / min). First, referring to 2 Discussed a definition of double clamped filaments to better understand the relationship between the first and second break zones. 2 shows a fiber 30 that has only continuous filaments, in one direction 81 moved and a breaking zone 34a by runs, such as B. the first breaking zone 34 in 1 , The break zone 34a extends over a length L1a between two groups of rollers 42a and 50a , The roll group 42a is driven at a first speed S1a, and the roller group 50a is driven at a second speed S2a higher than the speed S1a to define a speed ratio D1a = S2a / S1a. The speed of the fiber 30 will be in the breaking zone 34a increased, so that all continuous filaments in a feed end 85 are fed, in the length L1a to tear. Although the inlet end 85 in a position immediately behind the roller group 42a is shown, it designates a position either immediately before, immediately behind or in the nip of the roll group 42a , Throughout the present discussion, "upstream" refers to the direction from which the fibers come, and "downstream" refers to the direction in which the fibers move. The fiber has an elongation at break, expressed as a percentage, representing the percent elongation of a filament of the fiber in the direction of an attacking load just prior to stretch breaking of the filament. Typical elongation at break values for synthetic staple fibers prior to stretch consolidation may be about 300% for polyester and about 10% for polyester after stretch consolidation. At any time, such as B. to the in 2 As shown, there are some filaments that are torn, such as B. the filaments 84 . 86 and 88 , and some filaments that are stretched and not yet torn, such. B. the filaments 90 and 92 , The filament 84 is referred to as loose or floating, uncontrolled filament, since neither its inlet end 84a still its expiration 84b clamped and by the roller group 42a respectively. 50a is controlled. The filament 86 is referred to as a separately clamped uncontrolled filament with uncontrolled drain end, as it is only through a roll group 42a is clamped and controlled and an expiry 86a neither by the group of rollers 42a still through 50a is controlled. When the end 86a by a certain distance d from the central area of the fiber 30 protrudes, as shown, it may be at the roll group 42a or 50a pose a problem by winding around one of the rollers rather than moving in the direction 81 to move through the process. The filament 88 is referred to as a single clamped controlled filament passing through a roll group 50a clamped and controlled and a tail end 88a that does not pass through the roller group 42a still through 50a is clamped. The end 88a is less problematic than the end 86a because it is pulled through the process, rather than the end 86a to be bumped. The end 88a it is less likely to separate from the middle portion of the fiber than the end 86a , The filaments 90 and 92 are referred to as double-clamped carrier filaments, since they at the time shown by both groups of rollers 42a and 50a be clamped and controlled. They act as a "scaffold" to hold the other uncontrolled filaments in the mid-fiber range. They are under considerable tension, unlike the other filaments which are simply clamped, and therefore tend to hold the other filaments in the central region and the protruding ends as the end 86a narrow. At a next point in time, the filaments will be 90 and 92 Stretch tearing, but at this next time other filaments are clamped twice, such as. B. the filament 86 whose end 86a through the roller group 50a will be clamped. It is considered important to provide at least a minimum number of double clamped filaments at any one time in order to maintain a filament web and ensure good runnability of the process. The total number of filaments at the inlet end 85 is equal to the number of double clamped filaments plus the number of uncontrolled filaments, both loose and singly clamped filaments.

• – die Zulauffaser ist kontinuierlich
• – in der Zone gilt die Erhaltung der Masse
• – die Fasergeschwindigkeit an den Zulauf- und Ablaufgrenzen der Zone ist vorgegeben
• – Filamente Streckreißen unabhängig voneinander
• – Filamente Streckreißen gleichmäßig entlang der Zonenlänge

To predict the number of double clamped filaments under various process conditions, a modeling technique is used. The analytical expression is possible for a single zone with continuous feed filaments. The simulation applies the same basic principles to a multizone process where the feed to each zone can be continuous or discontinuous. The single zone results are in good agreement with each other. An analytical expression for a carrier index in a single break zone was derived from the basic principles with the following assumptions:

• - The inlet fiber is continuous
• - In the zone, the conservation of mass applies
• - The fiber speed at the inlet and outlet limits of the zone is specified
• - Filaments tear apart independently
• - Filaments stretch breaks evenly along the zone length

SI

= Anzahl der Trägerfasern/Anzahl der unkontrollierten Fasern

ln

= natürlicher Logarithmus

D

= Verstreckung = Geschwindigkeitsverhältnis in der Zone

e_b

= Reißdehnung der Faser, 10% wird ausgedrückt als 0,1

The derived expression for a "carrier index" is: SI = -ln (((D / (l + e b )) - 1 / (D - 1)) / (D · (1 - (0.5 / (1 + e b )))) In this mean:

SI

= Number of carrier fibers / number of uncontrolled fibers

ln

= natural logarithm

D

= Draft = speed ratio in the zone

e _b

= Elongation at break of the fiber, 10% is expressed as 0.1

To analyze a coupled process with stretch tears and stretching in multiple zones, a Monte Carlo computer simulation was developed. The simulation tracks the fiber movement through the process, where the fiber velocity in each zone (for example) is determined by the constraining roll groups. The defined kinematics determines the movement of simply clamped and double clamped filaments. Randomness occurs in the stretch breaking of double clamped filaments. According to the work of Ismail Dogu, "The Mechanics of Stretch Breaking" (Textile Research Journal, Vol. 42, No. 7, July 1972), the filament builds tension until the elongation at break is reached, and at that time randomly tears along the zone length. The stretch breakage of filaments is independent of other filaments in the fiber. Loose or floating filaments are treated in several different ways, from "ideal stretching" - filaments increase the speed of the feed roll group until the leading end reaches the drain roll group - to options where the speed of the filament depends on the velocity of adjacent filaments. The simulation results are in good agreement with the analytical predictions for the carrier index in individual zones, and the tensile stress in the process is in good agreement with the measured tensile stress in the process. The simulation model is in Matlab ^® 5.2 from Mathworks, Inc., Natick, MA 01760, down. Results can be determined with reasonable effort for 1000 filaments on a computer with Intel Pentium II 450 MHz processor. It is also feasible to process up to 3000 filaments with this system. The simulation of the filament length distribution for a two-zone tear procedure agrees well with the measured distribution.

How farther 2 As can be seen, when considering the number of double clamped filaments, it is useful to discuss the number, expressed as a percentage, of the number of double clamped filaments versus the number of uncontrolled filaments at the leading end of a zone length. B. the inlet end 85 the length L1a. The number of double clamped filaments is by definition at the inlet end 85 and at the end of the expiration 93 the zone length L1a the same. The number of uncontrolled filaments is always greater at the inlet end than at the end of the zone length L1a. At the downstream end of L1a, the discontinuous filament fiber has been stretched due to the velocity ratio D1a, so that the denier of the fiber at the downstream end is always smaller. With the same number of double-clamped carrier filaments, there are always more uncontrolled filaments at the outlet end, which must be supported or carried.

• – L2 = 0,33 L1
• – D1 = D2
• – D1 ≥ 2,0; D2 ≥ 2,0
• – Reißdehnung der Faser in beiden Reißzonen: e_b = 0,121

3 Figure 12 shows the results of a model simulation of a case where a break zone is used to achieve an overall speed ratio and another case where 2 break zones are used to achieve the same overall speed ratio. It is known that the total speed ratio for several zones can be calculated by multiplying the individual speed ratios for individual zones ((Dt = D1 × D2) or by calculating the total speed ratio (Dt = S3 / S1) 3 is the ratio of the number of double clamped carrier filaments, N _dg , to the total number of uncontrolled filaments, N _uc , counted at the feed end of the single zone and at the feed end of the second break zone for the two break zones (ie under the assumptions made for the two zones lowest value of N _dg / N _uc ). Other assumptions for the two zones are:

• L2 = 0.33 L1
• - D1 = D2
• - D1 ≥ 2.0; D2 ≥ 2.0
• - Elongation at break of the fiber in both break zones: e _b = 0.121

The curves in the figure relate the overall speed ratio to the ratio of the double clamped filaments to the uncontrolled filaments, N _dg / _Nuc . The case with a zone is in a dashed line 94 shown with rhombic data points, and the case with two zones is in a solid line 96 represented with square data points. As can be seen for all conditions of overall speed ratio, the two zone case always yields a higher ratio of double clamped filaments to uncontrolled filaments, which is believed to give better operability of the process.

Looking at the single tear zone in 3 It can be seen that with increasing speed ratio, the number of double clamped filaments decreases and with decreasing speed ratio, the number of double-clamped filaments increases. When applying this observation to the two Zones is a problem recognizable for achieving a given overall speed ratio. If one wants to achieve the number of double clamped filaments in the first zone by reducing the velocity ratio in the first zone, then necessarily the velocity ratio in the second zone must increase to maintain the same overall velocity ratio. This reduces the number of double clamped filaments in the second zone, which is undesirable. This problematic relationship is in 4 shown.

4 shows N _dg / N _uc along the vertical axis as in 3 However, on the horizontal axis, a relationship between the speed ratios of the two break zones is shown. Since a speed ratio of 1 for one zone means that the "feed speed" is equal to the "feed rate" and no stripping of filaments occurs, comparing the two speed ratios, the value 1 is subtracted from the speed ratio D1 of the first break zone and the speed ratio D2 of the second break zone , When the second speed ratio is equal to 1 in this case, the relationship (D2 - 1) / D1 - 1) is equal to 0, and the value where the curve intersects the vertical axis shows _Ndg / _Nuc for a single break zone to , For example, for the case Dt = 25 and D2 = 1, the value on the vertical axis is approximately equal to 0.01, ie equal to the value for Dt = 25, if the individual zone in 3 considered. The assumptions about the curves in 4 for the two zones are:
Dt = 25
D1 ≥ 2.0; D2 ≥ 2.0
L2 = 0.33 L1
e _b = 0.1

Since the speed ratio of the second zone is in the counter, the curve has 100 for the second zone the shape of the curves in 3 , Since the speed ratio of the first zone is in the denominator, the curve has 98 for the first zone one to the curves in 3 inverse form. When moving along the horizontal axis, it can be seen that the lowest value found in _{either of} the two zones for N _dg / N _uc (which determines a run-ability limit) is the thick solid line 102 is presented, which is a section 104 the curve 98 the first break zone for the values of N _dg / N _uc which are smaller than about 0.7, and a section 106 the curve 100 the second break zone for the values of N _dg / N _uc which are greater than about 0.7. When a level of 0.02, or 2%, is set as the desired minimum for N _dg / _Nuc , as by the line 108 This would indicate that a value of (D2-1) / (D1-1) of about 0.2 (where the dashed line 110 the horizontal axis intersects) to 2.0 (where the dashed line 112 the horizontal axis intersects) should be maintained under the conditions specified for this diagram. The optimal state would be about 0.7 (where the dashed line 114 the horizontal axis intersects) where both zones would have an N _dg / _Nuc value of about 0.04 or 4%. The value of N _dg / N _uc drops _rapidly below the optimum value of 0.7 for (D2 - 1) / (D1 - 1), and falls off less rapidly above 0.7. In addition, the value for N _dg / N _{uc is rapidly compensated} substantially above a value of about 5.0 for ( _D2-1 ) / ( _D1-1 ). An upper limit for (D2-1) / (D1-1) is therefore less critical than a lower limit to ensure good runnability of the tear process using 2 break zones.

The model simulation method was applied to other two-zone cases and used to examine the sensitivity of the optimal values for (D2-1) / (D1-1) and to maximize the number of double clamped fibers to obtain an acceptable value of N _dg / _Nuc to give good running ability. 5 shows the sensitivity of the elongation at break parameter of the fiber. Three different curves are recorded, showing the curves in 4 are similar, each curve representing a different value for the elongation at break e _{b of} the fiber. The curves representing the value of e _b = 0.1 are exactly the same as the curves in 4 , The assumptions for the three curves are:
Dt = 25
D1 ≥ 2.0; D2 ≥ 2.0
L2 = 0.33 L1

It can be seen that the number of double clamped fibers increases from 0.05 to 0.15 with an increase in e _b, but approximates the value for the optimum of (D 2 - 1) / (D 1 - 1) at about 0.7 the same stays where the dashed line 116 through the intersections of each zone curve pair and through the horizontal axis. If one wanted to improve the runnability of a given 2-break zone process, one could keep all process parameters except e _b at the same value and add some fibers having a higher elongation at break to improve runnability. However, this may change the properties of the yarn product.

6 shows the sensitivity to the ratio of the zone length parameters. There are three various curves are recorded, which show the curves in 4 are similar, with each curve representing a different value for the ratio of break zone lengths L2 to L1. The value of L2 = 0.33 L1 is the same as for the curves in 4 , The assumptions for the three curves are:
Dt = 25
D1 ≥ 2.0; D2 ≥ 2.0
e _b = 0.1

For zone 1, all three curves are the same and are superimposed. It can be seen that the number of double clamped fibers (ratio N _dg / _Nuc ) decreases with decreasing L2 from 0.5 L1 to 0.25 L1, and at the same time the value for the optimum of (D2 - 1) / ( D1 - 1) only slightly from about 0.5 to about 0.8. This change of (D2 - 1) / (D1 - 1) can be seen between the point where the dashed line 118 passing through the intersection of each zone curve for L2 = 0.5 L1 and through the horizontal axis, and the point where the dashed line passes 120 passing through the intersection of each zone curve pair for L2 = 0.25 L1 and the horizontal axis. It appears that in a two-break zone process, changing the ratio between L2 and L1 by reducing L2 from 0.5L1 to 0.25L1 can easily improve the operability of the process.

7 shows the sensitivity to the overall speed ratio parameter. Three different curves are plotted showing the curves in 4 are similar, each curve representing a different value for the overall speed ratio Dt. The curves representing the value Dt = 25 are exactly the same as the curves in 4 , The assumptions for the three curves are:
e _b = 0.1
D1 ≥ 2.0; D2 ≥ 2.0
L2 = 0.33 L1

It can be seen that the number of double clamped fibers increases from 50 to 4 with a decrease in Dt, but the value for the optimum of (D2-1) / (D1-1) remains approximately the same at about 0.7, where the dashed line 122 goes through the intersection of each zone curve pair and through the horizontal axis. To improve the runnability of a given two-zone process, one could keep all process parameters except Dt constant and reduce Dt to improve runnability. However, since the productivity of the process is highly dependent on Dt, this change to improve runnability can make the process uneconomical.

8th shows a schematic side view of another embodiment of the stretch breaking process line, compared to the embodiment of 1 which is a first breaking zone 34 , a second break zone 36 and a compression zone 38 has an additional draw zone 124 contains. The stretch zone can also function as an annealing zone. The fiber 30 that as well as in 1 several fibers 30a . 30b and 30c will now be at a process expiration 126 through a zeroth group of rolls 128 , the rollers 130 . 132 and 134 has been supplied to the process. The roller 132 is driven at a predetermined speed by a conventional motor / gear unit and a controller (not shown), and the rollers 130 and 134 be through their contact with the roller 132 driven. The fiber 30 becomes the first group of rolls 42 fed, causing the draw zone 124 between the roller groups 128 and 42 is defined. The stretch zone 124 has a length L4 between the nip of the roller 132 and the roller 134 that on the line 136 between their centers, and the nip of the rollers 44 and 46 that on the line 138 between their centers. The fiber velocity becomes within the draw zone 124 increased by passing the fiber through the roller group 128 with a feed rate Sf and through the roll group 42 is driven at a first speed S1 which is higher than the speed Sf. By comparing the fiber velocities at the two groups of rolls 128 and 42 a stretching speed ratio D4 = S1 / Sf is defined. There should be no slippage between the roller and the fiber; therefore, the fiber speed and roller surface speed are at the driven roller 132 equal to, and the fiber speed and the roller surface speed at the driven roller 46 are equal.

Within the draw zone 124 can be a fiber heating element 140 be present, which can take many forms; The shape shown here is a curved surface 142 which comes in contact with the fiber over a length that can be easily varied by changing the arc length on which the fiber rides over the surface 142 emotional. For longer heating times at a given fiber speed at the inlet end 126 and given stretch speed ratio D4, the arc and the contact length would be larger. The stretching of the fiber can occur as soon as the fiber is in the tensile stress of the draw zone 124 is exposed so that for certain polymers stretching or stretching of the fiber may occur while the fiber ge leave the nip of the feed rollers, such. B. the rollers 132 and 134 , For some polymers, the stretching occurs over a very short length, such as. Over less than 2.54 cm (1.0 inch). In this case, the heating element serves to anneal the stretched fiber rather than heating the fiber for stretching. If heating for stretching is required for this type of fiber, the rollers can 132 and 134 be heated. Other polymers may not stretch before being contacted by the surface of the heating element 140 experience a certain warming. The length of the draw zone is not critical, and it is primarily designed to be the heater 140 houses. In some cases of stretching zone operation, the fiber is stretched without heating (the heating element is turned off and retracted from contact with the fiber) and in other cases the fiber is heated as shown during the stretching process. In some cases, the fiber may have a draft ratio D4 of approximately 1, and the fiber may only be heated without being stretched. In this case, the draw zone would function as an annealing zone.

The The terms "stretch zone" and "fiber stretches" refer to Stretching a fiber with continuous filaments on a Way in which essentially no filaments are torn; the filaments remain continuous. In the stretching can be heating the fiber may or may not be included. The terms "annealing zone" and "annealing the fiber" refer to heating a fiber with continuous or discontinuous filaments with simultaneous restriction the filament length without essential stretching and can include a certain small advance of the fiber in the annealing zone, wherein D4 is a number that is slightly less than 1.0.

Using the method of 8th For example, a new product can be made which has the supply of at least two different fibers to the process and their combination prior to stretch break in the break zone, the differences between the fibers being differences in denier per filament and one fiber less denier per filament as 0.9 (den) and the other fiber has a denier per filament greater than 1.5 (denier). The two fibers pass through the tear and compaction zones together. The two different fibers can be combined as feed yarn by either spun a single fiber bundle with two different denier per filament (dpf) or two different fibers each with different denier per filament (dpf) are merged. In the draw zone, the elongation at break of the fibers should be similar. If this is a problem, one of the fibers could be partially pre-stretched to be compatible with the other, or both fibers could be fully pre-stretched and the fibers passed through the draw zone without stretching. The advantage of such a new product is that the structural stiffness of the yarn can be determined by the larger denier per filament (dpf) fiber, while the softness can be controlled by the smaller denier per filament (dpf) fiber. This overcomes certain problems with small denier per filament (dpf) yarns that have good hand but are too limp when processed into fabric.

9 shows a schematic side view of another embodiment of the stretch breaking process line, compared to the embodiment of 8th which is a stretching zone 124 , a first breaking zone 34 , a second break zone 36 and a compression zone 38 has an additional draw zone 144 contains. The stretch zone 144 will be between the second breaking zone 36 and the compression zone 38 inserted. The fiber 30 that like in 8th from the second break zone 36 is now leaving behind the roller group 62 supplied to the draw zone. The fiber 30 then becomes a fifth roll group 148 fed to the rollers 150 and 152 having, whereby between the roll groups 62 and 148 the stretching zone 144 is defined. The roller 152 is driven at a predetermined speed by a conventional motor / gear unit and a controller (not shown), and the roller 150 gets through her contact with the roller 152 driven. The stretch zone 144 has a length L5 between the nip of the roller 62 and the roller 68 who is on a line 80 between their centers, and the nip of the rollers 150 and 152 , The fiber velocity becomes within the draw zone 144 increased by passing the fiber through the roller group 62 at a speed S3 and through the roller group 148 is driven at a fifth speed S5, which is higher than the speed S3. By comparing the fiber velocities at the two roll groups 62 and 148 A stretch speed ratio D5 = S5 / S3 is defined. Since no slippage should occur between the roller and the fiber, the fiber speed and roller surface speed are at the driven roller 66 equal to, and the fiber speed and the roller surface speed at the driven roller 152 are equal. The length L5 should be approximately equal to the length of the adjacent upstream break zone, in this case in the illustrated configuration equal to the length L2 of the second break zone. This condition means that very few fibers are broken in the draw zone and, instead, the discontinuous filaments of the fiber leaving the second break zone only slide past each other to reduce the denier of the fiber by one to the draw used ratio D5 proportional amount decrease. In the same way as for the uniform stretching of short staple filaments of a fiber in a PCT patent application WO 98/48088 by Scheerer et al. In some cases, a controlled proportion of filaments may be torn to produce a more uniform yarn. Such a system is also used in the catalog CAT. No. 22P432 97-1-4 (NS), published by Murata Machinery, Ltd., entitled "Muratec No. 802HR MJS, Murata Jet Spinner."

The terms "draw zone" and "stretch" of the fiber refer to increasing the fiber velocity in a zone for the main purpose of decreasing the denier of the discontinuous filament fiber so that more than 80% of the fibers remain the same length, that is in that at most 20% of the fibers are torn. It is intended that the draw zone may be at various locations as long as it is upstream of the densification zone, e.g. For example, it may be between the first break zone and the second break zone. A procedure similar to that in 8th was performed, and data were collected to determine the limits of good runnability found in 10 are shown. 10 shows the curves of 4 wherein the left vertical axis is stretched and a right vertical axis is added to allow the recording of some concrete procedural cases that have been performed to determine the good running limits. Good runnability was indicated when the process could be started and run with the production of an acceptable stretch pulp fiber for at least 5 minutes at a feed rate of 0.9144 m / min (1 yard / min) (the drainage rate from the second break zone was determined by machine considerations limited to about 137.16 m / min (150 yards / min)). Poor runnability was indicated when filaments of fiber wrapped around any rolls in the process. The densification step has been omitted to simplify the process, as this step usually does not contribute significantly to runnability issues. The fiber was behind the roll group 62 ( 8th ) taken from the process and received by a Abfallabsauggerät. The tension was indicated at a position within the first break zone L1 at a distance of about 15.24 cm (6 inches) from the feed end L1, using a guide attached to a load cell which lightly touched the fiber. When operating at low speed ratios, the tension signal was monitored for scatter and spikes. Tension spikes greater than twice the desired tension signal, which occurred at a frequency of more than twice per minute, indicated poor runnability and jerky operation, whether or not the process collapsed within 5 minutes. The parameters held constant for all test runs are:
e _b = 2.38 feed fiber
e _b = 0.12 to the break zone
L2 = 0.33 L1
L1 = 48 inches (121.92 cm); L2 = 40.64 cm (16 inches)
L4 = 16 inches (66.25 inches)
Drawing speed ratio D4 = 2.43
Stretch length L4 = 112
Stretch temperature = 188 ° C over a 30.48 cm (12 inch) contact area.

The Feedstock consisted of 3 fibers of continuous polyester filaments of 7320 den, each supplied from a cheese.

D1 and D2 were both varied to obtain the maximum overall speed ratio Dt by setting D1 to a value and varying D2 until the process stopped running. The last running point with no breakdown of running ability was the point of good running ability in 10 is recorded as a function of the maximum Dt value and of (D2 - 1) / (D1 - 1). 10A shows the recorded data. The circled data points in 10A are the ones in 10 were recorded. Next to each circled data point is the Dt value and in brackets the value of (D2 - 1) / (D1 - 1). All circled points for the maximum overall speed ratio are between a curve for Dt = 20X and Dt = 50X. A curve for the optimum operating point for (D2-1) / (D1-1) = 0.4 for different total stretch ratios is also shown at 155; the maximum overall speed ratio for good runability along this line has been in point 157 determined at 42.8X. For different materials and different zone lengths, these data would be different. The finish used on the fiber is also a factor in runnability. Excessive sizing impairs the independent mobility and tearing of the filaments in the break zones, and a complete breakdown of the fiber occurs; if too little finish, the static charge is problematic, and there is an increased roll winding formation. A finish level of less than about 0.1% is preferred, and less than about 0.04% is more preferred. A typical 0.04% finish has a mixture of an ethylene oxide condensate of a fatty acid, a pelargonic acid terminated ethoxylated propoxylated alcohol, the potassium salt of a phosphate acid ester, and the amine salt of a phosphate acid ester. Some Polymers, such as. As aramids and fluoropolymers require no finishing. Other finishes that may be useful for stretch pulp fiber are disclosed in US-A-4080778 to Adams and Japanese Patent Publication 58 [1983] -44787 to Hirose et al. to find.

Like back out 10 recognizable, allows the connection of the data points with the line 158 a comparison of the test data with the 4 extracted simulation curves 98 and 100 , It can be seen that the concrete runnability data (experiment) follow the general trend indicated by the simulation, the optimum operating point (D2-1) / (D1-1) = about 0.7 being the same as the dashed line 114 Are defined.

A device necessary for the operation of the method according to 1 . 8th and 9 can be used is in 11 shown. The inlet fiber 30 is made from one or more containers 160 fed fibers, or alternatively may be feed fiber of one or more cheeses 162 be supplied. The fiber 30 happens some Vorkardenführungen 164 , which can be used to merge multiple fiber ends and allow the distribution of the fiber in a flat band. The fiber then passes over a guide roller 166 to a roll group 128a , the 4 rollers 168 . 170 . 172 and 174 and a pinch roller 175 to the yarn at the inlet end of a draw zone 124 securely clamp when threading the fiber. All rollers 168 - 174 are driven by a conventional electric motor / gear unit and a controller (not shown), and the pinch roller 175 is made by contact with the roller 168 driven. The end of the draw zone 124 is through another group of rollers 42a defines the four rollers 176 . 178 . 180 and 182 and a starting pinch roller 184 having. All rollers 176 - 182 are driven by a conventional electric motor / gear unit and a controller (not shown). The starting clamp 184 is made by contact with the roller 182 driven. It serves to thread the fiber into the process and then out of contact with the roll 182 withdrawn. Between the roll groups 128a and 42a is an electric heating element 140 with a curved surface 142 arranged, which may have a variable contact length with the yarn, as with reference to 8th discussed. An electric power source (not shown) is attached to the heating element.

On the roll group 42a follows a first break zone 34 with a roller group 50a at the end of the run, with the roller group 50 in the 1 and 8th is identical. Within the first break zone 34 are an electrostatic neutralizer 186 adjacent to the stretched and cracked fiber 30 and a swirl nozzle 188 attached, by the fiber 30 is going through. The electrostatic neutralizer bar is powered by an electrical power source (not shown) and is the type sold by Simco, model no. ME 100. Point source antistatic devices such. B. the devices 187 , instead of or in addition to the rod 186 to eliminate static charges, especially near the roll groups. Because the filaments in the fiber are in the break zone 34 Stretch tears and stretched into a lower denier fiber rub against each other and create a troublesome electrostatic charge which causes the ends of the filaments to be repelled from the central region of the fiber. This looseness of the fiber and protruding ends causes problems with the breakup of the fiber and loose filaments winding on one of the downstream rolls. As mentioned above, one way to combat this problem is to use metal surfaces properly on some of the pinch rolls. Another method of combating these problems is to gather the loose filament ends in the break zone and adjacent to the exit pinch rolls and direct them toward the fiber core so as to constrain the loose ends in the lateral directions around the core. that they are within a distance from the center of the core, which is not greater than the distance of the core center from the respective end of the tear-zone exit pinch rollers to minimize the winding of the loose ends onto the exit pinch rollers. It is important to use this control method in the first break zone, where loose filament lengths may be longer and unsupported over a greater distance. Its application is also advantageous to the second breaking zone, where still loose fibers are present. A vortex nozzle 188 is one way to implement this method.

How out 12 recognizable, directs the swirl nozzle 188 a gaseous fluid jet to gently swirl loose filaments around the central fiber region or core, which is a flat ribbon-like structure. The swirl nozzle is in 12 shown in more detail. The swirl nozzle 188 has a body 192 with a feed end 194 , an expiry date 196 and a cylindrical bore 198 on, extending through the entire length of the body 192 extends. The fiber 30 goes through the hole 198 on her way to the group of rollers 50a (please refer 11 ). A fluid channel 200 goes through the body and stands at the inlet end 194 of the body in fluid communication with the bore 198 , The fluid passage intersects the bore so that the fluid is approximately tangential to the bore and angled toward the drain end 196 of the body is initiated. That way, inside the hole 198 a counterclockwise fluid flow (from the end 196 seen from the generally generated by the spiral flow path 202 is hinted at. This fluid flow tends to loose filaments coming from the central area of the fiber 30 go out to wind around the fiber core to eliminate long loose ends that can wind on downstream rollers. The wound filaments are loosely gathered around the fiber core. For convenience is in the body 192 in the longitudinal direction of the bore 198 a threading slot 204 attached to the threading of the fiber 30 into the bore of the swirl nozzle to facilitate.

Another way of realizing the method of merging the loose filament ends in the break zone and adjacent to the exit pinch rolls and redirecting them to the fiber core is to use a trough as in US Pat 34A and 34B shown. A trough 450 has a shaped end 452 on, adjacent to a pinch roller group such. B. the roll group 50a ( 11 ), and spaced therefrom at the end of the first break zone 34 is arranged. The trough has a longitudinal cavity 454 on that for taking up the fiber 30 is dimensioned in the zone and a width 456 which has the loose filaments 458 and 460 on the sides of the fiber core 462 merges and prevents them from extending outwardly to the ends of the pinch rollers in the roller assembly. The fiber-facing surface of the cavity is an electrically conductive surface. The pinch roller 54a has ends 462 and 464 on, and the pinch roller 52a has ends 466 and 468 on. The center of the fiber core is at 470 indicated, and the trough directs the loose filaments to the Faserker 462 out that the loose ends, such. B. the laterally projecting around the core ends are limited to a distance from the core center, which is not greater than the distance 472 the core center from the end 468 the exit pinch roller 52a and the distance 474 from the end 464 the exit pinch roller 54a ; in this case, the smaller distance 472 decisive. In addition, the loose ends, such. B. the laterally projecting around the core ends 460 , limited to a distance from the core center that is not greater than the distance 476 the core center from the end 466 the exit pinch roller 52a and the distance 478 from the end 462 the exit pinch roller 54a ; in this case, the smaller distance 476 decisive.

The trough 450 can only be placed adjacent to the pinch rollers at the exit of the zone and extend therefrom for a short distance, or it can extend almost the entire length of the zone 34 to keep control of the loose filaments throughout the zone. The trough 450 Optionally a cover 480 It is particularly important, however, that the trough laterally enclose the filaments to prevent them from extending to the ends of the pinch rolls where they readily wind on the pinch rolls. If a cover is used, it should provide access for an air ionizer.

Like back out 11 recognizable, joins the group of rollers 50a a second break zone 36 with the roller group 62a at the end of the run, identical to the roll group 62 in the 1 and 8th is. Within the second break zone 36 are an electrostatic neutralizer 206 near the stretch and tear fiber 30 and a swirl nozzle 208 arranged by the fiber 30 is going through. This is similar to the configuration of the first break zone just discussed. Also, in the second break zone is near its feed end and next to the roll group 50a a suction nozzle 212 arranged. The suction nozzle 212 provides a gentle flow of gaseous fluid in the direction of movement of the fiber 30 to get out of the roll group 50a catching loose loose filament ends and driving them forward so that they do not impact on the rolls in the roll group 50a wrap. The suction nozzle 212 is a guy by Airvac as Model No. ITD 110 can be obtained. Such a suction nozzle can also be in the first break zone 34 near the roll group 42a used when the fiber entering the zone has some discontinuous filaments.

After the roll group 62a follows a stretching zone 144 with a roller group 148a at the end of the run, with the roller group 148 in 9 is identical. Within the draw zone 144 are a suction nozzle 214 , Braking rods 216 and management staffs 218 arranged. The deceleration rods provide some resistance to stretching the filaments to give the fiber a more uniform denier. The provision of a Verwübungsungsüse such. B. the Verwirbelungsdüse 208 , in flow direction before and adjacent to the roll group 148a can be useful.

After the roll group 148a follows a compression zone 38 with a roller group 74a at the end of the run, with the roller group 74 in the 1 . 8th and 9 is identical. Within the compression zone 38 are a suction nozzle 220 and a potting nozzle 83a arranged. In practice, the Verwverwungsungsüse 83a usually in the compression zone 38 at a distance from the roll group 148a from arranged about 1/3 to 1/2 of the length of the compression zone. 26 shows the Verwverwungsungsüse 83a in perspective view, and 27 shows a sectional view with a in the fiber channel 320 entering cracked fiber 30 , The fiber channel 320 preferably has a cross-section in the shape of a rounded triangle, from the entrance end 322 seen from. The nozzle 83a has a first groove wall 324 in an entrance guide area 326 on that in conjunction with an outer entry surface 328 at the entrance end 322 causes a Coanda effect (redirecting tangential flow); and a second groove wall 329 ( 27 ) in an exit guide surface 330 the nozzle, in conjunction with an outer exit surface 332 at exit end 334 the fiber channel 320 causes a Coanda effect. A clamping slot 336 cuts the fiber channel 320 , How out 27 recognizable, performs a fluid inlet channel 338 the fiber channel 320 Fluid to fluidize the fiber for compression into a yarn. The fluid channel 338 is at an angle 340 to the outlet end of the nozzle at the outlet end 334 arranged in the direction of the fiber movement through the nozzle to minimize the suction of fluid from the inlet end of the fiber channel. In addition, the yarn channel 320 the swirl nozzle at an angle 342 to the fiber path 344 between the roller group 148a and 74a ( 11 ) so that fluid exiting the inlet end of the yarn channel is directed downwardly away from the fiber path. The guides 346 and 348 can be used to help guide the fiber through the nozzle. This transfer of fluid exiting the upstream end of the yarn channel minimizes the spread of any loose filaments in the fiber as the fiber enters the swirl nozzle. Such a Verwverwelungsdüse 83a is more fully described in US-A-6052878 to Allred et al. described here by reference. In the present embodiment, further filament connection nozzles would function. Another such nozzle is that described in the Murata Jet Spinner Catalog and PCT Patent Application WO 98/48088 already mentioned above. Another potting nozzle is disclosed in US Pat. No. 4,825,633 to Artz et al. described here by reference. The fiber 30 becomes a compacted yarn after passing through the densifier (such as one of the nozzles just discussed or another device disclosed above) 32 ( 11 ), which has a good cohesion and good strength.

The type-nozzle will be described below with reference to FIG 28 further discussed, which shows the left half in section along the fiber path and the right half in plan view. In US-A-4825633 the nozzle is referred to as a pneumatic torsion element which can be controlled in the manner described in US-A-5048281. The pneumatic torsion element 83b has an injector component or first nozzle 350 with a spinning hole 351 and a torsion component or second nozzle 352 with a spinning hole 353 on. The two components are shared by a holding device 354 fixed in relation to each other, in addition to a first evacuation chamber 356 and a second evacuation chamber 358 are housed for cleaning abrasive particles associated with the fiber. The cracked fiber 30 First, the bore of the first nozzle happens 350 , It is believed that this first die causes further transport of the fiber and some twisting of loose filaments on the outer periphery of the twisting fiber core being formed by the second die. The fiber then passes through the bore of the second nozzle 352 , It is believed that this second nozzle causes twisting of the filaments in the fiber core in the direction of flow in front of the second nozzle and through the first nozzle without causing inter-filament entanglement in the yarn. This understanding is consistent with the operation of the murata double-jet assembly described in an article in The Journal of the Textile Institute, 1987, No. 3, pp. 189-219, entitled "The Insertion of Twist" in Yarns by Means of Air Jets "by P. Grosberg, W. Oxenham and M. Miao; the article consists of Part I: Experimental Investigation of Spinning with Air Nozzles; and Part II: Twist Distribution and Twist Distribution Velocity with Air Nozzles. The first evacuation chamber 356 is adjacent to the exit end 360 the first nozzle 350 arranged and stands on one side 362 in fluid communication with a vacuum source and on an opposite side 364 in fluid communication with the atmosphere. Air coming from the side 364 to 362 flows across the path of the fiber removes loosely torn filaments and polymer or finishing powder and dust from the fiber path. The fiber then passes through the second nozzle 352 and a tension opening 366 and the second evacuation chamber 358 , Both the tension opening and the second evacuation chamber are close to the exit end 368 the second nozzle 352 arranged. The second evacuation chamber 358 contains a clamping slot in the longitudinal direction 370 , which can be covered after tensioning by a cylindrical cover (not shown). Such a cover may be around the outside surface 372 the holding device 354 Turn to cover the slot and release when the surface is one the chamber 358 surrounding cylindrical surface, which matches with the cover. The second evacuation chamber is on one side 374 in fluid communication with a vacuum source and is at the clamping slot 370 (if the cover is open or missing) and on the ends 376 and 378 in fluid communication with the atmosphere. Air coming out of the ends 376 and 378 and through the slot 370 flows out, flows along the fiber path and removes loosely cracked filaments and polymer or finishing powders and dust from the fiber path. The functioning of the torsion element 83a is not dependent on the first and second evacuation chambers, but these contribute to reliability element by keeping it clean.

The first nozzle or injector component 350 has pressurized gas, preferably air passing through a conduit 380 in a ring channel 382 is fed, which directs the fluid to a plurality of pressure fluid channels, such. B. 384 and 386 , The channels 384 and 386 cut the spin hole 351 with a diameter d ₁ in a known manner at a tangent to the bore diameter and at an angle 388 obliquely to the fiber movement direction through the bore. The entrance opening 389 the bore 351 the first nozzle 350 may have a straight cylindrical shape, as shown, or may be tapered and have notches to affect the propagation of the twist in the fiber. The second nozzle or torsion component 352 also has an air supply through a pipe 390 in a ring channel 392 on, which conducts the fluid to a plurality of pressure fluid channels, such. B. 394 and 396 which the bore 353 with a diameter d _D cut. The first nozzle 350 has a characteristic distance l ₁ from the end 360 to a channel, such. B. 386 , and the second nozzle 352 has a characteristic distance l _D from an entrance end 398 to a channel, such. B. 396 , The first nozzle 350 is at a distance "a" from the second nozzle 352 arranged, measured between pressure fluid channels where they intersect the spin hole of each nozzle. This distance is set for the particular fiber to be processed and may be larger for fibers with a large average filament length and smaller for fibers with a small average filament length. The first and second nozzles 350 and 352 be by fasteners, such. B. clamping screws (not shown), adjustably fixed in common holding device 354 to facilitate the setting of the distance "a". Alternatively, each nozzle may have independent retainers and be mounted spaced on the machine frame (not shown). For any process for densifying discontinuous filament fibers having an average filament length greater than 10.16 cm (4.0 inches), and preferably greater than 15.24 cm (6 inches), it has been surprisingly found that U.S. Pat Uniformity of the yarn strength is maximized when the distance "a" is set in proportion to the average filament length of the fiber.

Regarding the device of 11 will be in the compression zone 38 instead of the device 83a the pneumatic torsion element 83b used, and the suction nozzle 220 will be removed. Like back out 28 recognizable, becomes the first nozzle 350 as close as possible to the pinch roller group 148a ( 11 ), wherein the distance from the nip to the location in the first nozzle, where the fluid channels 384 and 386 the spin hole 351 cut, about 2.54 cm (1.0 inches). The second nozzle is set at different distances "a" from the position of the first nozzle where the fluid channels 394 and 396 the spin hole 353 to cut.

35 Figure 12 shows a yarn tenacity plot for a yarn having an average filament length "avg" with data points for each average length taken at different spacings "a" between the fluid passages in the first and second nozzles 350 respectively. 352 in 28 was measured. For each "a" distance, multiple yarn samples are taken and an average number of grammages per denier (g / den) is determined by the Lea Product method. For those with 8.0; 8.9 and 17.5 curves can be seen in the diagram that the strength maxima are at a certain value where the distance between the nozzles is yy inches. For comparison with the mean filament length for the yarn being processed, a ratio avg / yy is formed which is useful for selecting the appropriate value for "a". Repetition of this test for several different yarn lengths gave values of "a" in the range of 0.74 avg to 1.53 avg, or preferably from 0.5 avg to 2.0 avg, the mean and preferred value being 1.1 avg , These results will be discussed further below with reference to tests 20-23. Another test (not shown) wherein the second nozzle remained spaced from the pinch rollers and the first nozzle was moved close to the second nozzle resulted in lower strength values for the compacted yarn, so that the important relationship is believed to be the distance between the nozzles and not just the distance of the second nozzle from the pinch roller.

How out 11 recognizable, is following the roll group 74a the compressed yarn to a winding machine 222 directed. Between the roller group 74a and the winding machine 222 are a suction nozzle 224 and a groove guide roller 226 arranged. The winding machine has a dancer arm and a grooved roller 228 which are mounted on a control device (not shown) for controlling the winding machine speed, a traversing device 230 for the transverse movement of the yarn 32 along an axis of a yarn package 232 and a driven spindle 234 on. The winding machine is of conventional construction, which requires no further explanation for the expert familiar with the winding technique.

11 Fig. 10 shows a method in which all the functional zones, which in one way treat the yarn, are arranged substantially in a straight line path. 11 shows as functional zones the stretching zone 124 , the first breaking zone 34 , the second breaking zone 36 , the stretching zone 144 and the compression zone 38 all in a line from left to right, with the fiber following a substantially straight path through each function zone, the path in each function zone defining a direction unit vector (a vector with a direction and magnitude 1) that is a peak in the direction of fiber movement and has an end. The process works well, but takes up a large footprint. For production machines in a factory, the optimal use of footprint is important to keep costs low. 32 shows a ripper 400 for a method in which the fiber path is convoluted by one or more of the functional zones, such that when a path vector in a first functional zone is arranged end-to-end with a path vector in a next functional zone, an included angle between 45 ° and 180 ° °, which leads to a compact footprint for the process.

How out 32 recognizable, the tearing device 400 on: a stretching zone 402 between roller groups 404 and 406 , a first breaking zone 408 between roller groups 406 and 410 , a second break zone 412 between roller groups 410 and 414 and a compression zone 416 between roller groups 414 and 418 , The compacted yarn is added 420 wound up by a winding machine system. Similar to the device in 11 also contains the device 400 a heating element 140 , an electrostatic neutralizer bar 186 , Swirl nozzles 188 and 208 , a compacting device 83 , such as B. 83a ( 26 and 27 ) or 83b ( 28 ) and various other transport nozzles, guides, pinch rollers, etc. Also, between the heating element 140 and the first break zone 408 a heat shield 417 arranged. In order to achieve flexibility in the manufacture of various products is included 419 behind the stretch zone 402 and before the first break zone 408 a second fiber feed exists. A third fiber feed point is included 421 behind the second break zone 412 and before the compression zone 416 available. During operation, an inlet fiber occurs 30 from a creel (not shown) in position 424 in the direction of a path vector 426 with a tip 425 and an end 427 into the ripper 400 one. The path vector 426 is not a path vector for a functional zone because the fiber is being transported at this point and is not being treated in any way. The fiber passes through the roller group 404 and moves in the direction of a path vector 428 through the functional zone for stretching the fiber, the draw zone 402 , Then the fiber passes through 30 the roll group 406 and moves in the direction of a path vector 430 through the functional zone for the stretch break, the first break zone 408 , The fiber then passes through the roll group 410 and moves in the direction of a path vector 432 through the functional zone for the stretch break, the second break zone 412 , Then the fiber passes the roll group 414 and moves in the direction of a path vector 434 through the functional zone for the compression, the compression zone 416 , The compacted yarn 32 is then on the winding machine 420 wrapped into a package.

The 33A , B and C show the arrangement of vectors for defining the folding process that takes place between the paths for the functional zones. In 33A are the way vectors 428 and 430 successive functional zones abutted end to end. The path vector 430 is arranged so that its end coincides with the end of the path vector 428 coincides, and the included angle between the two rectilinear vectors is at 436 displayed and is about 180 °. In 33B are way vectors 430 and 432 successive functional zones merged end to end. The path vector 432 is arranged so that its end coincides with the end of the path vector 430 coincides, and the included angle between the two rectilinear vectors is at 438 displayed and is about 90 °. In 33C are way vectors 432 and 434 Merged end to end. The path vector 434 is arranged so that its end coincides with the end of the path vector 432 coincides, and the included angle between the two rectilinear vectors is at 440 displayed and is slightly larger than 90 °. Also, if only two functional zones were present in the ripper, a rupture zone and a compaction zone, then the path vector would extend 430 the fiber in the first break zone 408 in one direction, and the path vector 434 the fiber in the compression zone 416 is folded so that it extends in a direction opposite to the path in the breaking zone, that is rotated by about 180 ° direction. This leads to a compact arrangement that occupies a minimal footprint. It is not necessary that all successive functional zones are folded, but in order to save space, the fiber path should be folded at least two consecutive zones as they pass from one zone to the next.

This folding of the fiber paths through the functional zone, so that when a path vector in a first functional zone end to end with a path vector in a next functional zone an included angle between 45 ° and 180 ° is defined, leads to a compact footprint for the device for practical Execution of the tear process. In a case with more than two functional zones, several included angles may each be present between successive functional zones where the fiber path is folded. In the case of multiple convolutions and included angles, the folded path system according to the invention is alternatively defined if the sum of the absolute values of all individual included angles between successive functional zones is preferably min at least 90 ° and more preferably at least 180 °. In the 32 The arrangement shown is only one folding arrangement for a tearing process, and the concept of folded paths is applicable to other tearing methods and another way vector arrangement.

That through the device of 11 Yarn produced is a staple yarn having discontinuous filaments and a denier which can be readily used in textile end-uses without further processing than conventional dyeing or the like. The length-related mass or denier of the staple yarn product is typically approximately less than or equal to 1000 denier, or in other words, it is a staple yarn having at most 500 filaments per cross-section, the length-related mass may be more than 1000 denier. It is believed important that the laid-fiber process be relatively economical in terms of denier, thereby eliminating a costly winding step and allowing the use of undrawn fibers which are sometimes difficult to successfully wound into a package. This is in contrast to a sliver tearing device, such. The one discussed in the above document US-A-4924556. It is believed that the process of the invention utilizes laid feed fiber 30 for a tearing operation to produce a compressed yarn 32 is particularly advantageous. Such a method comprises withdrawing a fiber at a speed greater than 1.0 m / min from a container containing continuous filament fiber laid therein, the fiber having a denier of 2000-40000 denier, and the fiber Container contains 4.54-90.7 kg (10-200 lb) of fiber, and feeding the fiber into a fiber break zone and tearing the fiber in the break zone by increasing the fiber speed within a given zone length in a speed ratio greater than 2.0 and Densification of the fiber downstream of the break zone to form a staple yarn. Preferably, before being ruptured, the fiber is stretched and tempered in a stretch zone upstream of the rupture zone by increasing the fiber velocity within a predetermined stretch zone length and heating the fiber within the length.

The laid fiber is preferably obtained particularly economically by a modified process for operating a single polymer feed system staple fiber spinning machine which feeds a plurality of normally combined spin positions to produce a single coarse cable product which is collected in a container to later convert to staple fiber become. 29 Figure 1 illustrates such a system including a staple fiber spinning machine 500 with, for example, 10 positions, such as the individual items 502 . 504 . 506 . 508 and 510 , with the machine at 511 supplied with polymer by a single feed. The positions all become a coarse cable product 512 United in a large container 514 is filed. In a conventional batch conversion process, the container becomes 514 , which collects over 453.6 kg (1000 lb) of product, combined with other containers and undergoes a conversion process using 516 is characterized and eventually leads to staple fiber in a carding, combing and spinning system 518 is spun to yarn. How out 30 As can be seen, the improvement includes the operation of the modified staple fiber spinning machine 501 having at least about 10 spinning positions to simultaneously produce a plurality of fine cable products rather than a coarse cable product, the fine products each making up less than about 20% of the coarse cable product. In 30 is provided that at least 2 positions, and preferably at least 5 positions, z. For example, the positions 502 . 504 . 506 . 508 and 510 producing individual fine cable products and the remaining 5 or more positions could continue to produce a coarse cable product or, as in 31 It can be seen that all positions of the modified batch spinning machine 503 could produce individual fine cable products. A single fine cable product 30 at least 500 Fibers in a spinning position, wherein the product in an individual container 160 collecting about 9.07 to 90.7 kg (20 to 200 pounds) of fine cable product. The device for receiving the individual fine cable product has a laying device 524 or a winding machine (not shown); Preferably, a laying device is used to unstretched product so in the container 160 to catch that the product can be stored, transported and removed for further processing. A cross-wound bobbin on a spool core of a winding machine is also a container from which the product can be stored, transported and removed for further processing.

The new operating procedures for the pile spinning machine closes also a change of fiber product properties for at least one spinning position that makes the fine product so that the Fiber product characteristics differ from the other spinning positions, which produce either the fine product or the coarse product. To these changed Fiber product properties can another denier per filament, another finish, another Color by direct color injection at the spinning position, another Filament cross section or other fiber differences include usually are available in an individual spinning position.

The new operating method of the staple spinning machine further comprises providing means for processing the fine cable product from at least one spinning position to convert the fine cable product into a spun yarn. Such a device, which in the 30 and 31 is shown, preferably comprises the stretch-breaking machine according to the invention 522 on, which from the Legefaserbehälter 160 is fed. Alternatively, the machine could include the process disclosed in US-A-4667463 to Minorikawa or the finish of US-A-4 080 778 to Adams or the like, thereby converting continuous filament fibers into discontinuous filament staple yarns. Any position on the staple fiber spinning machine, such. For example, the position 502 , could the need of possibly 10 spinning positions, such. B. the position 526 , on a stretch-breaking machine 522 so that many stretch-pulling machines, such as 522 and 522a each having a plurality of positions with fiber from a single staple fiber spinning machine 500 could be supplied.

The feed yarn 30 can be achieved in the hopper by a laying device as disclosed in US-A-4221345 160 according to the 11 . 30 and 31 be provided, or it may by a in the 13 and 14 shown device can be provided. 13 shows a laying device 236 that is a leader 238 , a roller 240 , a drive roller 242 , a suction nozzle 244 , a fiber distribution rotor 246 , a rotor drive 248 , a container 250 and a container shuttle 252 having. The fiber 30 may come from a staple fiber spinning machine for continuous synthetic filaments, such as. B. from the staple fiber spinning machine 501 or 503 in the 30 respectively. 31 , The leadership 238 The fiber leads to a roller / drive roller combination with the rollers 240 respectively. 242 where the fiber makes at least one full turn, as indicated by the arrows 254 and 256 shown before the suction nozzle 244 in the direction of the arrow 258 is supplied. The fiber becomes an inlet channel through a gaseous fluid in the suction nozzle 260 in the rotor 246 propelled by a rotor drive 248 is set in continuous rotation.

The fiber passes through the rotor 246 and leaves it through a channel exit 262 , The fiber then moves in a spiral path 264 down into the container 250 , As a portion of the container gradually fills with fiber, the container shuttle shifts the container slowly under the rotor to gradually fill the container with reciprocally-guided layers of spirally-laid fiber. Such a lay-up device can operate at speeds consistent with conventional spinning positions and lay down fibers so that they can be removed from the container at low speeds consistent with stretch breaking speeds.

14 shows a detail sectional view of the rotor 246 , the one body 266 having. The entrance channel 260 is located at the top of the body 266 in the center of rotation of the body 266 and is with the channel exit 262 through an angled channel 268 connected by the fiber 30 ( 11 ) and fluid from the suction nozzle 244 ( 13 ) can happen easily. A compensation hole 270 is opposite the channel exit 262 provided to balance the rotor and to minimize the vibration during rotation.

The in the 1 . 8th and 9 illustrated method using the device of 11 may produce a staple fiber yarn having a denier of less than or equal to 1000 denier or a staple fiber yarn having at most 500 filaments per cross section. Such a yarn has an exceptional filament length distribution when operating the tear zones as described above to provide a particular stretch yarn. The exceptional stretch yarn has a certain average filament length, a maximum filament length and a filament length range. Such a stretched yarn has a useful number of filament ends per inch. A significant proportion of these numerous filament ends are in the form of protruding ends which protrude from the central portion of the yarn and impart a desirable hand or "feel" to the yarn. In a preferred embodiment, the yarn has a number average (compared to weight average) filament length greater than 15.24 cm (6 inches), the maximum filament length of 99% of the filaments is less than 63.5 cm (25 inches). and the average 98% of the filament lengths define a length range greater than or equal to the mean length. The range is equal to the difference between the maximum length of the mean 98% samples and the minimum length of the mean 98% samples. The yarn may also be characterized as a compacted chemical fiber of discontinuous filaments of varying length, with the filaments being intermixed in the longitudinal direction of the yarn to maintain yarn uniformity, the average length avg of the filaments being greater than 15.24 cm (6 inches). and the fiber has a filament length distribution characterized in that 5% to less than 15% of the filaments have a length greater than 1.5 times the mean length avg. Preferably, the filament length distribution also comprises 5% to less than 15% of the filaments whose length is less than 0.5 avg.

• – e_b = 3,5, Zulaufgarn zur Streckzone
• – e_b = 0,247, Zulaufgarn-Wert nach dem Strecken und dem Eintritt in die erste Reißzone
• – e_b = 0,1 (geschätzter Wert beim Eintritt in die zweite Reißzone)
• – L1 = 129,54 cm (51,0 Zoll); L2 = 42,926 cm (16,9 Zoll); (L2 = 0,33 L1)
• – D1 = 3; D2 = 2; ((D2 – 1)/(D1 – 1) = 0,5
• – Streckgeschwindigkeitsverhältnis D4 = 4,2
• – Strecklänge L4 = 284,48 cm (112 Zoll)
• – Strecktemperatur = 188°C über eine Kontaktfläche von 30,48 cm (12 Zoll)
• – Zulaufmaterial war eine Faser von 9147 Denier, Nylon mit kontinuierlichen Filamenten von 6,6 dpf (Denier pro Filament) aus einem Behälter mit gelegter Faser.

15 FIG. 12 is a plot of the filament length distribution for a yarn made according to the following process parameters. FIG.

• - e _b = 3.5, feed yarn to the draw zone
• - e _b = 0.247, feed yarn value after stretching and entering the first break zone
• E _b = 0.1 (estimated value on entering the second break zone)
• L1 = 129.54 cm (51.0 inches); L2 = 42,926 cm (16.9 inches); (L2 = 0.33 L1)
• - D1 = 3; D2 = 2; ((D2-1) / (D1-1) = 0.5
• Stretching ratio D4 = 4.2
• Stretch length L4 = 284.48 cm (112 inches)
• Stretching temperature = 188 ° C over a 30,48 cm (12 inch) contact surface
• Feed was a 9147 denier fiber, 6.6 dpf continuous filament nylon (denier per filament) from a fiber-laid container.

The histogram in 15 represents the filament length distribution of the concrete yarn sample and is with 271 designated. The filament lengths were pulled out of the fiber before densification so that they could be easily removed. No stretching was used. The filament lengths were determined by the method described in US-A-4118921 in the sections entitled "Average Fiber Length", "Fiber Length Distribution" and "Fiber Length Histogram", which is incorporated herein by reference. By measuring and calculating the denier, it was known that about 192 filaments were contained in the fiber cross section coming from the second break zone; therefore, 500 filaments were removed from the new fiber end and the lengths were recorded and grouped in 2.54 cm (1 inch) increments. The procedure for determining this filament number was to repeat the procedure described under "average filament length" after each batch of 100 filaments. This resulted in the histogram 271 the fiber length and frequency of 15 , The model simulation of the procedure was set up in the same way as the actual test procedure, by the curve 272 from 15 predict the filament length distribution shown. As can be seen, the simulation of the filament length distribution comes close to the actual filament length distribution. For the specific test, the number average filament length was 11 inches (27.94 cm) and for the simulation, the average filament length was 11 inches (28.194 cm). For the particular test, the length of the average 98% of the filament lengths was 7.62 cm (3 inches) to 45.72 cm (18 inches) for an area of 38.1 cm (15 inches). For the simulation, the lengths were 3.5 inches to 19.5 inches for a 16 inch area. For the specific test, the maximum length of 99% of the filaments was 45.72 cm (18 inches), and for the simulation, the maximum length was 49.53 cm (19.5 inches). Simulation values in these cases were within 10% of the actual values. The number of filaments less than 0.5 times the mean avg and the number greater than 1.5 times the mean were measured and simulated. The results are 8.2% smaller than 0.5 avg and 5.0% larger than 1.5 avg. The simulated results are 11.16% smaller than 0.5 avg and 10.27% larger than 1.5 avg. These simulation results do not agree well with the measurements. The filament length distribution measurement results for the top and bottom foothills of the distribution are considered to be statically unreliable because far too few filament samples were taken in the foothills of the distribution. In the simulation, a total of 40,000 filaments are sampled, containing many tail filaments. In the measured distribution, only a total of 500 filaments were measured, which contained few tail filaments. Alternatively, more filaments could be taken in the measured sample. The data in 15 are also listed in Table I.

• – mittlere Filamentlänge = 27,92 cm (11,0 Zoll) und 28,194 cm (11,1 Zoll), die ≥ 15,24 cm (6 Zoll) sind.
• – mittlerer 98%-Bereich = 38,1 cm (15 Zoll) und 40,64 cm (16 Zoll), die ≥ 27,94 cm (11,0 Zoll) bzw. 28,194 cm (11,1 Zoll) sind
• – maximale 99%-Filamentlänge = 45,72 cm (18 Zoll) und 49,53 cm (19,5 Zoll), die ≤ 63,5 cm (25 Zoll) sind.
• – Filamentlängen von weniger als 1,5 × avg = 5% und 10,27%, die zwischen 5% und weniger als 15% liegen
• – Filamentlängen von weniger als 0,5 × avg = 8,2% und 11,16%, die zwischen 5% und weniger als 15% liegen

Values of the actual test and simulation that are within the limits of the yarn product of the present invention are as follows:

• Average filament length = 11 inches and 11.1 inches, which are ≥ 15.24 cm (6 inches).
• Mid 98% range = 15 inches and 16 inches, which are 11.1 inches and 11.1 inches, respectively
• Maximum 99% filament length = 45.72 cm (18 inches) and 49.53 cm (19.5 inches), which are ≤ 63.5 cm (25 inches).
• - Filament lengths of less than 1.5 × avg = 5% and 10.27%, which are between 5% and less than 15%
• - Filament lengths of less than 0.5 × avg = 8.2% and 11.16%, which are between 5% and less than 15%

The Table I below shows further simulated operating conditions, including some simulations of comparative examples, and shows various Operating parameter ranges that are within the limits of the invention lie. Some concrete tests with concrete and simulated results are also included.

In Table I, the measurements given in inches ('') can be converted to centimeters by multiplying the listed value by 2.54. Examples CE1 and CE2 are simulated comparative examples operating at a total speed ratio of Dt = 25. In example CE1, the break zone length is L1 = 76.2 cm (30 inches), and the proportion of double-clamped filaments is low. If the filament distribution from CE1 in 16 it is noted that the maximum length of 99% of the filaments is over 63.5 cm (25 inches). In CE2, the break zone length is 25.4 cm (10 inches) and the average filament length is less than 15.24 cm (6 inches), which is believed to contribute to a lower strength yarn when swirling is used for densification , The filament distribution of CE2 is in 17 where it can be seen that the maximum length of 99% of the filaments is smaller than 63.5 cm (25 inches), which is an improvement over the example CE1. Since the proportion of double-clamped filaments in both of the single-zone-of-zones comparative examples is low, runnability problems are expected to occur in the practice of these examples. In tests similar to simulation conditions, performance problems occurred in individual break zones at speed ratios of approximately 20 for zone lengths down to 50.8 cm (20 inches) and approximately 5 for zone lengths of 25.4 cm (10 inches) on.

Examples A, B, CD, E and F are simulation examples which were also carried out at a total speed ratio Dt = 25. Example A illustrates a high speed ratio of D2 = 10 in the second break zone which resulted in a low level of double clamped filaments in the second break zone, although the proportion is greater than 50% greater than that in the individual break zones of the comparative examples. Example A1 shows that decreasing the speed ratio in the second break zone and increasing the ratio in the first break zone gives a favorable value for (D2-1) / (D1-1) of 2.0. It is expected that this will lead to an improvement in runnability over Example A. Example B shows a state where the first and second break zones are operated at the same speed ratio 5. This gives good results for the proportion of double clamped filaments, although the second break zone has a lower value, so runability problems would more likely occur there. Example B1 shows that by reducing the speed ratio in the second break zone and increasing the speed ratio in the first break zone, one could expect an improvement in runability of the second zone so that both zones have the same high proportion of double clamped filaments. From the diagram of 4 For a value of (D2 - 1) / (D1 - 1) of 0.7, the approximate value of 3.8% is obtained. Example C shows the effect of a high speed ratio in the first break zone which reduces the proportion of double clamped filaments there compared to Examples A and B. At the level D1 = 10, however, the proportion of double-clamped filaments is higher than in the second break zone, when in Example A D2 = 10. This is also indicated by the specific data in 10A supported, given the point of maximum runnability 157 for the optimum value (D2 - 1) / (D1 - 1) of 0.7. At this point, where Dt = 4.28, the value for D1 is 7.5 and for D2 it is 5.7. It appears that runnability problems associated with double clamped fibers occur in the second break zone at a lower speed ratio than in the first break zone. The filament distribution for Example C is in 18 shown. It has a mean length = 6,51 inches (≥ 15,24 cm (6 inches)); an average 98% range = 25.4 cm (10 inches) (≥ 16.54 cm (6.51 inches)) and a maximum 99% filament length = 29.21 cm (11.5 inches) (≤ 63, 5 cm (25 inches)). The simulated results for the number of filaments smaller than 0.5 times the median and number greater than 1.5 times the median are 13.43% smaller than 0.5 avg and at 12.06% greater than 1.5 avg. This serves as an example of the invention and has a good number of filament ends per inch. Examples D, E and F show similar results to Examples A, B and C, respectively, when using longer first and second break zones L1 and L2. Since L2 = 0.33 L1 in each case, the effect on the proportion of double-clamped filaments is small. The mean filament lengths increase as expected.

Examples G, H, J and K are simulation examples carried out at a higher total speed ratio of Dt = 30. Different zone lengths were used, but for examples G and H, L2 = 0.33 L1. They perform better with respect to double-clamped filaments than Examples B and C, respectively, because the increase in Dt was not large enough to greatly reduce the proportion. The filament distribution for Example G is in 19 shown. It has a greater average length = 25,654 cm (10.1 inches); a wider 98% center = 38.1 cm (15 inches) and a larger maximum 99% filament = 44.45 cm (17.5 inches) as Example C. The simulated results for the number of filaments with a smaller one Lengths greater than 0.5 times the mean and numbers greater than 1.5 times the mean are 15.49% less than 0.5 avg and 14.30% greater than 1.5 avg , Example G accordingly has fewer filament ends per inch than Example C, although the reduced denier of the feed yarn and the increased speed ratio also contribute to the lower value. In Examples J and K, L2 = 0.2 L1, but this change is not enough to make much difference compared to Examples B and C.

20 shows the process scheme of 9 in which a new shredded fiber product is produced can, by at the end of the expiration 300 the draw zone 144 , which is also the inlet end of the compression zone 38 is, an additional feed fiber 31a is introduced. Because the fiber 31a is exposed to any stretching, the filaments in the fiber 31a be continuous or discontinuous. When using continuous filaments, these high-strength filaments with low elasticity may be such. As an aramid fiber, or they may be filaments with high elasticity, such as. A spandex-type fiber or a 2GT (1,2-ethanediol (or ethylene glycol) esterified with terephthalic acid) or a 3GT (1,3-propanediol (or 1,3, propylene glycol)) 3GT ( esterified with terephthalic acid) polyester fiber. A preferred spandex-type fiber is one having elastic filaments having an elongation at break of greater than about 100% and an elastic recovery of at least 30% from an elongation of about 50%. These extra fibers 31a can the fibers 30 are added, which preferably contain a polymer, such as. As nylon, polyester, aramid, fluoropolymer or Nomex ^® (brand name for a fiber and paper with raw materials of isophthalyl chloride, metaphenylene diamine). Kevlar ^® aramid fiber of continuous filaments has been combined with polyester in one product and elastic Lycra ^® fiber of continuous filaments has been combined with polyester in another product.

21 shows the process scheme of 9 in which a new stretch-knit fiber product can be made by standing at the end of the drain 302 the draw zone 124 , which is also the inlet end of the first break zone 34 is, an extra fiber 31b is introduced. This is useful if fibers 31b that do not require stretching, the stretched fibers 30 should be added. Both fibers 30 and 31b be in the first break zone at the same time 34 torn down and treated together throughout the remainder of the process. Such additional fibers 31b are preferably selected from the group of polymers belonging to the aramid, fluoropolymer and Nomex ^® and are fibers 30 added, which preferably includes a polymer from the nylon or polyester group.

22 shows the process scheme of 9 wherein a novel stretch-knit fiber product can be made by adding a first additional feed fiber 31b at the end of the expiry 302 the draw zone 124 is introduced, which is also the inlet end of the first breaking zone 34 is, and also a second additional fiber 31a at the end of the expiry 300 the draw zone 144 is introduced, which is also the inlet end of the compression zone 38 is. This forms a useful combination of fiber features as described with reference to FIGS 20 and 21 discussed. A particularly preferred embodiment is the introduction of a fluoropolymer as the first additional fiber 31b , a spandex-type fiber as the second additional fiber 31a , wherein both additional fibers with a fiber 30 made of polyester. Such a yarn product can be used as a textile yarn for weaving or knitting socks. Another product combined discontinuous polyester as a first elongated feed fiber with a first additional feed fiber of Kevlar ^® aramid, which is torn together with the polyester, and that combination combined with a second feed fiber of elastic Lycra ^® fiber of continuous filaments to to form a three-component yarn.

The stretch breaking process of the present invention is applicable to the mixing of fibers which may have been processed to some extent, such as e.g. By coloring or a surface treatment that gives the fiber a certain visual property that can be perceived by the naked eye. Stretch breaking is a viable option for making specialty yarns without including a lot of extra steps, such as those described in US Pat. B. when mixing staple fiber are required, where the sliver must first be prepared by chopping (cutting), mixing, carding, combing and the like, as in 516 and 518 in 29 has been presented in general. In this conventional system, a large amount of feed fiber must be prepared to make the process worthwhile, since cleaning the process equipment after each product pass is very labor intensive and time consuming. In the case of stretch breaking, only a small amount of feed fiber need be prepared for mixing with another fiber, and switching to another product mix requires virtually no cleaning other than replacing bobbins in a creel. This is especially useful in making small amounts of mixed color yarn. How out 9 recognizable, the applicants have found that by feeding a fiber 31c with a first color, different from that of a second inlet fiber 31d different, a different colored yarn can be made, which is a mixture of the two colors. By "different colors" is meant two colors, which are essentially non-white and non-beige variants, although one fiber may have a white or beige and the other a clearly non-white, uncoloured color. The intent is to combine two distinctly different colors together and then to stretch-break and then condense to create a new, different color. The standard E-284 of the ASTM Committee E12 describes a device for distinguishing neutral colors, such. White and beige, based on a brightness measurement, with white and beige having a brightness of more than 90%. It also allows for a distinction of hue and hue to detect a color difference by using CIELAB units, with distinctly different colors would have a difference in CIELAB units of at least 2.0. By mixing at least two different fiber colors, with only one color having a brightness of more than 90% and the others having a color difference in CIELAB units of at least 2.0, a yarn having a new color is produced from the at least two different feed fibers , The color of the new yarn is significantly different than the color of each feed fiber. During further processing to cloth-like material, the mixed color comes out as a gentle erikavioletter look. Other visual differences that may be blended with Applicants' stretch-tearing process are fibers with a marked difference in reflectivity, absorbency, wettability, and the like.

23 shows a schematic side view of the production line of 1 , which is the addition of an annealing zone 124a behind the compression zone 38 illustrated. The annealing zone was higher at the reference to the draw zone 124 with heating device 140 discussed in 8th is shown and used without significant speed change ratio. This may be useful in a process where the final shrinkage of the yarn must be controlled to a predetermined value and post-bake annealing is the most direct way to accomplish this. It may also be useful if the feed fiber is composed of two different fibers and the heat treatment on tempering causes each fiber in the yarn to react differently to produce a special effect yarn, if the shrinkages of the fibers are different and the differential shrinkage produces a puffy or curling yarn.

24 shows a photomicrograph of a filament of a novel cracked product, the end 304 each filament is split as a result of the stretch breaking process. The feed fiber is a manmade fiber of continuous polyester filaments that is known under the trademark Coolmax ^® from EI DuPont and is described in US-A-3914488 by Gorrafa and US-A-5736243 by Aneja. As well as out 25 Recognizable showing a cross section of the filament, the filament has a width 306 and has several thick sections within this width 308 . 310 and 312 on, through thin sections 314 and 316 connected to each other. It is believed that the stretch breaking process for cutting through the thin sections 314 and 316 at the filament ends when the filaments tear. The severing occurs over a length 318 of at least about three filament widths, so that one or more thick sections, such. B. the section 308 , from the other thick sections, such. B. the sections 310 and 312 , are split off at the filament ends. This is believed to result in the appearance and feel of having more filament ends present in the yarn, thereby improving the "feel" of a fabric made from the yarn.

In Table II, the measures given in inches ('') can be converted to cm by adding the led value is multiplied by 2.54. The measurements given in yards per minute (yd / min) can be converted to meters per minute (m / min) by multiplying the value listed by 0.9144. Table II shows various products made in accordance with the teachings of the invention, generally those described in U.S. Pat 9 illustrated method using the in 11 illustrated device has been practiced. With feedstock totaling about 1500-20000 denier, yarns of about 100-400 denier are produced. Fibers that are stretched in the process are usually fully stretched so that the elongation at break when entering the first break zone is about 10%.

The test 1 shows a process state for the production of a nylon yarn with an end denier of 137 , The procedure was similar to the method of 9 a draw zone, a first break zone, a second break zone, a draw zone and a compression zone. The feed yarn came from a legebehälter, such as at 160 in 11 (denoted by P in Table II), and the finished yarn product was wound by a winding machine as in 222 in 11 , The compression nozzle 83a ( 9 and 26 ) had a fluid opening at an angle 340 from 60 ° in the direction of yarn movement, for all tests using this nozzle 83a the same was. The outer surface 328 the nozzle is at a distance of about 15.24 cm (6 inches) from the nip between the rolls 150 and 152 the roll group 148 arranged. It is believed that this method produced a yarn having the characteristics of the invention having an average filament length of at least 15.24 cm (6 inches), with the maximum length of 99% of the filaments being less than 63.5 cm (25 inches) and the average 98% of the filament lengths define a value of the length range greater than or equal to the average filament length, and from 5% to less than 15% of the filaments is greater than 1.5 times the length have the average filament length. Test 2 shows a similar process state to Test 1, which has a draw zone, a first break zone, and a second break zone, which are approximately the same as those used to make the present invention 15 The product was completed by further processing the fiber into a 209 denier yarn in a draw zone and a densification zone. It would be expected that this product would have a similar distribution of filaments as those in 15 has shown. Test 3 shows a product made using a polymer having a coefficient of friction between the filaments of less than 0.1, which is a fluoropolymer manufactured by EI DuPont de Nemours & Company (hereinafter "DuPont") under the tradename ^Teflon® . In the method, a Teflon ^® -Stapelfaserprodukt was prepared, which is difficult produced economically by other means. At the roller groups 50a . 62a and 148a from 11 an "omega" sling was used, as in 1A shown to control the slippage of the fiber in the roll groups. The inlet fiber was as well as in 11 from a cheese 162 fed (designated W in Table II). The procedure differed from Test 1 in that the fiber was not heated or stretched in the draw zone. It is believed that this product has an average filament length greater than 15.24 cm (6 inches), and that the other properties are similar to those in Test 1. Test 4 shows a product prepared by a similar method to that described in 21 was prepared illustrated where a high strength aramid fiber (DuPont trademark Kevlar ^®) in upstream of the roll group 42 ( 42a in 11 After the stretching of the polyester fiber (Dupont trademark ^Dacron® ), aramid and polyester were then torn, stretched and densified to produce a blended yarn having a denier of 397. On the roll groups 50a . 62a and 148a from 11 an "omega" sling was used, as in 1A to control the slippage of the fiber in the roll groups, since the aramid fiber required a high force for stretch breaking. It is considered that this product has filament-length characteristics similar to those of Test 1.

Test 5 shows a product as prepared in Test 3 by a similar method where an aramid fiber (DuPont trademark Kevlar ^®) and a fluoropolymer (DuPont trademark Teflon ^®) were fed together and nor drawn in the draw zone, not heated ; the draw zone served only as a convenient way to transport the fibers to the first break zone. The Kevlar ^® - and Teflon ^® fibers were then stretch broken, drafted, and compressed to prepare a mixed yarn having a denier of 274th At the roller groups 50a . 62a and 148a from 11 an "omega" sling was used, as in 1A to control the slippage of the fiber in the roll groups, since the aramid fiber required a strong force to break and the fluoropolymer needed more surface contact to prevent slippage. Such a yarn is useful for the manufacture of reinforcing fabric useful in synchronous belts in the industry where high strength and low abrasion are appreciated. It is believed that this product has similar filament length properties to those in Test 1.

Test 6 shows a product that was prepared by a similar method as in test 5 where an aramid fiber (DuPont trademark Kevlar ^®), and a high temperature fiber (DuPont trademark Nomex ^®) fed together and are nor drawn in the draw zone neither heated; the draw zone served only as a convenient way to transport the fibers to the first break zone. The Kevlar ^® - and Nomex ^® fibers were then torn together, stretched and compacted to make a blended yarn with a denier of 230. At the roller groups 50a . 62a and 148a in 11 an "omega" sling was used, as in 1A in order to control the slippage of the fiber in the roll groups, since the aramid fiber required a strong force for stretch breaking. It is believed that this product has similar filament length properties as in Test 1.

Test 7 shows a product which was prepared by a similar method as in Test 3, in which introduced an aramid fiber (DuPont trademark Kevlar ^® and was further stretched in the stretching zone, not heated, the draw zone was only used as a convenient way to transport the fibers to first break zone. an "omega" wrap used. one Kevlar ^® yarn with a low denier of 101 was produced that would be difficult to produce economically by other means to produce. It is believed that this product has filament length characteristics such as those of test 1.

Test 8 shows a product produced by a similar method to that shown in Test 4, but in the flow direction upstream of the roll group 42 ( 42a in 11 ) after stretching the polyester fiber (DuPont trademark ^Dacron® ) a fluoropolymer fiber (DuPont trademark ^Teflon® ) was introduced. Fluoropolymer and polyester were then torn, stretched and densified to produce a 278 denier blended yarn. Such a product may be useful for the manufacture of socks which minimize the formation of blisters on the feet of the wearer. It is believed that this product has similar filament length properties to those of Test 1.

test 9 shows a similar one Method as in Test 1, but using polyester fiber. A denier yarn of 274 is made. It exists the view that this Product similar Filament length characteristics as that of Test 1 has.

Test 10 shows a product prepared by a similar method to that described in 20 is produced, wherein in the flow direction in front of the roller group 148 ( 148a in 11 Was introduced an elastic continuous filament fiber (DuPont trademark Lycra ^®)) after stretching, stretch-breaking and stretch of the polyester fiber (DuPont trademark Dacron ^®). The Lycra ^® fiber was stretched, in order to stretch by about 100% prior to being combined with the Dacron ^® fiber and both compressed together, the Lycra ^® filaments remain continuous. When the finished yarn was kept free of tension, the Lycra ^® fiber pulled together and produced a bulky crimped yarn that was highly elastic.

Test 11 shows a similar procedure to that in Test 9 except that the polyester filaments had a similar cross-section as in 25 and wherein a yarn having a denier of 277 with split ends as in 24 was generated. It is considered that this product has filament-length characteristics similar to those of Test 1.

test 12 shows a similar one Method as in Test 1, but wherein the feed fiber of two different fibers each with different color. The colored fibers were combined before stretching and put together as a single fiber bundle stretched and torn. The first fiber had a clear pink color, and the second had a clear purple color. It is believed that this Both fibers each have non-neutral colors with a brightness of less than 90% and a color difference of at least 2.0 CIELAB units exhibit. The resulting yarn had a color that was distinct differed from each of the feed fiber colors, and it is believed that at Processing this yarn into a fabric makes the fabric an eric violet Look.

test 13 shows a similar one Method as test 12, but the pink fiber through a light gray fiber, which is believed to be one neutral color with a brightness of more than 90%. The resulting yarn had a color that was distinct from each of the Feed fiber colors differed, and the yarn itself had a distinct ericaviolettes look.

Test 14 shows a similar method to that of 20 , Where a first feed fiber of Kevlar ^® was pulled (as in test 7) and in the flow direction immediately upstream of the rolling group 148a in 11 a second Kevlar ^® fiber was fed at continuous filaments. The continuous filaments were consolidated with the discontinuous cracked Kevlar ^® filaments to form a reinforced staple yarn having a denier of 311th

Test 15 shows a similar procedure as in 22 Wherein a Teflon ^® fiber in upstream of the roll group 42 ( 42a in 11 ) (Is also supplied as in test 8) and a Lycra ^® fiber in the flow direction in front of the roller group 148 ( 148a in 11 ) is supplied. The Teflon fiber is stretch broken and drawn together with the Dacron ^® fiber, and this mixed discontinuous filament fiber is compacted together with the Lycra ^® fiber with continuous filaments, as discussed in Test 10th This results in a stretchy, bulky, low friction yarn which would be useful in the production of stretch socks that minimize blistering.

Test 16 shows a similar procedure to Test 1 in which two separate feed fibers were fed to the process to produce a coarse feed fiber of approximately 20,000 denier at the entrance to the draw zone. In the draw zone, two temperature zones were on the heating element 140 from 11 used. A first zone was 60.96 cm (24 inches) long and at 100 ° C, followed by a second 30.48 cm (12 inches) long zone at 188 ° C. At a total speed ratio of the process of greater than 70X, a yarn having a denier of 277 was produced.

Test 17 illustrates a product made in accordance with the teachings of the invention, particularly that described in U.S. Pat 8th illustrated method using the device according to 11 was practically carried out. To set up the procedure of 8th using the device of 11 became the plug-in zone 144 and the roll group 148a in 11 removed, and the compression zone 38 became near the roll group 62a postponed since in the process of 8th no stretch zone is used. The compacting device of 28 was used, which was alternatively referred to as a double jet device, and the process was carried out with a total extension of 48 to produce a 192 denier product having a low L2 / L1 ratio of 0.25. Table III shows the parameters of the double nozzle.

In Table III, the measures in inches ('') can be converted to centimeters by multiplying the listed value by 2.54. Test 18 is the same procedure as Test 17 except for the swirl nozzle 26 and 27 was needed. The feed yarn consisted of two black eggs dyed 6280 denier nylon cables each, which were combined before the draw zone to give a final denier of 186 yarn. The process operated at a total draft of 67.4 for a high exit velocity of 277 m / min (303 yd / min), which approximates the speed limitations of the machine used for the test. It is expected that using the method of the present invention and a higher speed machine could achieve higher speeds in excess of 500 yd / min (457.2 m / min). Test 19 shows results similar to Test 18, with a final exit velocity of 246 m / min (269 yd / min) and a ^Dacron® product of 198 denier. Tests 20, 21, 22 and 23 were performed with a similar construction to Test 17 to determine the preferred distance "a" between the nozzles of the compacting apparatus of FIG 28 to investigate. Each test was set up to produce a yarn with a different average filament length determined by simulation. For each average length of filament, multiple passes were made, varying the distance "a" between the nozzles of the compactor by leaving the first nozzle N1 in position at a distance of 4.37 cm (1.72 inches) where the Fluid channels intersect the fiber well; the second nozzle was shifted to different positions and a sample of compacted yarn was taken. In the sample for each position, the strength was measured by a Lea Product method, and the strength was recorded for each position of the second nozzle in grams per denier. Test 20 was set up to produce a yarn having an average filament length of 22.6 cm (8.9 inches) as determined by simulation. The results were in 35 plotted as the curve marked 8.9. The maximum strength occurred at a nozzle pitch "a" of 22.61 cm (9.2 inches) as recorded in Table III for Test 20. This gave a ratio a / avg of 1.03. A simulation of the filament distribution was also performed for the conditions used in this test and is shown in Table I for Test 20. The simulation suggested that 12.4% could be expected for the distribution of filaments longer than 1.5 times the mean filament length; for the distribution of filaments with a length of less than 0.5 times the average filament length 14.7% could be expected. Test 21 was run as test 20 performed except the break zone lengths were changed so that a yarn made of Dacron ^® polyester fiber with an average filament length of 44.45 cm (17.5 inches) was produced. This set of conditions was also applied at a high L2 / L1 ratio of 0.58. The results were in 35 plotted as the curve marked 17.5. The maximum strength occurred at a nozzle pitch "a" of 33.02 cm (13.0 inches) as recorded in Table III for Test 21. This gave a ratio a / avg of 0.74. A simulation of the filament distribution was also performed for the conditions used in this test and is shown in Table I for Test 21. The simulation suggested that 12.4% could be expected for the distribution of filaments longer than 1.5 times the mean filament length; for the distribution of filaments less than 0.5 times the mean filament length, 13.9% could be expected. Test 22 was run as the test run 20, except the break zone lengths were changed to produce a yarn of Dacron ^® polyester fiber with an average filament length of 16.256 cm (6.4 inches). The results were in 35 plotted as a curve with the label 6.4. There was no definite value for the maximum strength; the curve was essentially flat, except for an indentation to a strength of about 0.8, which was an estimate because the sample made at this 10.16 cm (4 inch) distance was so weak that no strand of full size could be wound up for the normal lea product test. Either the nozzle pitch is not critical to the strength at small average filament length, or there was an unexplained problem in the test. A simulation of the filament distribution was also performed for the conditions used in this test and is shown in Table I for Test 22. The simulation suggested that 12.3% could be expected for the distribution of filaments longer than 1.5 times the mean filament length; for the distribution of filaments less than 0.5 times the mean filament length, 13.9% could be expected. Test 23 was performed by tearing the fiber not in the first breaking zone but only in the second breaking zone to simulate a break zone process. The test was set up to produce a yarn having an average filament length of 20.32 cm (8.0 inches). The results were in 35 recorded as a curve labeled 8.0. Maximum strength occurred at a 30.99 cm (12.2 inch) nozzle pitch "a" as recorded for Test 23 in Table III. This gave a ratio a / avg of 1.53. A simulation of the filament distribution was also performed for the condition used in this test and is shown in Table I for Test 23. The simulation suggested that 18.4% could be expected for the distribution of filaments longer than 1.5 times the mean filament length; for the distribution of filaments less than 0.5 times the average filament length, 18.3% could be expected. This single break zone product has product properties which are outside the limits of the invention with the use of two break zones, but shows that the nozzle pitch has an optimum value for best yarn tenacity and the inventive nozzle pitch is effective in a variety of processes. by making a yarn having an average filament length of more than 6 inches.

If the results of tests 20, 21, 22 and 23 are considered the value for the distance "a" between the first Nozzle and the second nozzle in the range of 0.74 to 1.53, or approximately 0.5 times to 2.0 times the average filament length for fibers / yarns with a medium filament length greater than about 15.24 cm (6 inches). When averaging over the three values of "a", the preferred value for "a" is approximately equal to 1.1 times the mean Filament length. Although test 22 did not show any point of maximum strength He points to a point of reduced strength, which in the structure of the Procedure could be avoided if the teachings of the invention complied with and the nozzles were set to the preferred value of 1.1 avg. from that would become a value "a" of 1.1 x 16.256 = 17.78 cm (7.0 inches). This reduces the position Strength of 12.7 cm (5.0 inches) avoided.

Test 24 was carried out with a similar construction to Test 17 using the compacting apparatus according to 28 and the L2 / L1 ratio of 0.35 was used to make a yarn having a mean filament length of 17.0818 cm (6.7 inches).

test 25 uses a similar Procedure like Test 17. The feed material in Test 21 is an elastic one Bicomponent yarn, each filament having a round cross-section having one half of cross-section 2 GT polyester and the other cross-section half 3 GT Polyester. Such feedstock is disclosed in US-A-3671379 by Evans et al. described here by reference becomes. Related patents from other authors are US-A-3562093; 3454460 and 2439815. The two different polymers in the cross-section have different shrinkage properties after spinning on, so that after the heat treatment the fiber is a crimp fiber is, wherein the filaments to a spiral-shaped, resilient structure frizz. Before the heat treatment to activate the latent elasticity of the fiber, the fiber still a considerable elasticity or ripples on what used to be to a problem in the production of staple fiber yarn under application conventional Combing and carding devices has led. As a result, it is believed that staple fiber yarn is made of bicomponent fiber in the textile industry is not known. The resulting multifilament yarn is very springy and has a considerable elasticity of tension-free Condition up to maximum tension, where the total elasticity without plastic Deformation of the filaments is removed. This elasticity is called percentage curl development CD characterized, which develops with damp heat and after the Guidelines in the above mentioned documents US-A-3671379 and 3454460 can be measured. The finished yarn must be heat treated after stretch breaking to restore his latent elasticity and his final to achieve elastic properties.

Test 25 shows a process state for making a bicomponent yarn from 2 GT polyester and 3 GT polyester components (referred to as BC 23) with a final denier of 160 denier. The method comprises a heat treatment zone, a first break zone, a second break zone, and a compression zone, similar to the method in FIG 8th ; a stretch zone is not used. The supply yarn comes from the 12 cheeses with 100 den yarn, each of the spool 162 in 11 are similar. The feed yarn has been pre-stretched but not heat treated to develop the latent elasticity of the fiber, although the fiber has some partial elasticity or crimp. The finished yarn product was characterized by an in 11 illustrated winding machine 222 wound. The compacting device used is that in 28 illustrated double-nozzle type. The at 164 The tensioning device shown was adjusted so that it provided a sufficient tension for the feed yarn, so that the entire partial extension (crimping) on the roller 168 was removed from the feed yarn. The yarn is passed through the fiber heater 140 while maintaining the tension, but without stretching the filaments at a temperature of 180 ° C heat treated. Although the fiber in the draw zone 124 was not stretched, surprisingly, heating of the fiber was necessary to maintain good operability in the break zones. The yarn was torn in the zones D1 and D2 and torn again and then without stretching to the compression nozzle 83b to make a yarn with a denier of 160 denier. The yarn was then wound on a spool with sufficient tension, as in 222 so that extensibility in the yarn has been substantially eliminated. In order to develop the elastic character of the yarn, the yarn must be heated to about 100 ° C to produce a spirally wound elastic (curled and curled) yarn structure of good bulk and elastic recovery. This heating may be carried out in a separate step, or the yarn may be woven into a fabric, and the heat may be supplied by the fabric dyeing process. It is believed that the discontinuous filament crimp yarn develops a crimp of about 35-40%, as measured by the method described in the aforementioned US-A-3671379 to Evans et al. is described. It is believed that this method produces a yarn where the crimp and curl are out of register due to the random stretch tearing of the filaments, so that this yarn is used in the manufacture of a weak "orange peel effect" stretch staple fiber fabric (a fabric surface speckled appearance, similar to the surface of an orange) would be very useful. Fabric with curled or curled yarn, often not except Covering have an orange peel effect.

Test 26 shows a process state for the preparation of a bicomponent yarn of 2 GT and 3 GT components (BC 23) with a 50:50 ratio of the components, the densified yarn having an end denier of 176. The method comprises a stretching and annealing zone (tempering zone), a first breaking zone, a second breaking zone and a densification zone, similar to the method in FIG 8th ; a stretch zone is not used. The feed yarn comes from 24 cheeses and forms an undrawn yarn with a denier of 4714 denier. The finished yarn product was wound up by a winding machine, as in 222 in 11 shown. The compression swirl nozzle 83a ( 26 and 27 ) had a fluid inlet opening at an angle of 60 ° in the direction of yarn movement. The clamping device at 164 was set so that it exerted sufficient tension on the feed yarn so that the total extensibility of the roll 168 was removed from the feed yarn. The yarn is passed through the fiber heater at a temperature of 160 ° C 140 pulled and stretched in a ratio of 3.0X. The yarn was torn in zones D1 and D2 and torn again and then became a compacting die without stretching 83a promoted to a yarn of 176 to build. The yarn was then wound on a cheese, as in 222 ( 11 ). If the yarn was heat treated with steam (or hot air) to raise the temperature to 100 ° C, which would serve to re-develop the shrinkage and curl in the filaments, then the yarn would be expected to have a CD of would have about 50-60%. This is slightly higher than what would be expected with the yarn of Test 25 which was compacted with the double nozzle assembly making a bundle yarn. If the same fiber had only been stretched and not torn, it is believed that it would have a CD of about 55-65% which is only slightly higher than the staple fiber yarn of the present invention having a better hand than a bicomponent yarn having continuous filaments.

The Results of tests 24 and 25 are surprising in that a torn Staple fiber yarn with good runnability made of either pre-stretched or unstretched fiber can be by first removed the entire elasticity of Zulaufgarns with bias and then the yarn is heated to both the pre-stretched as also the straight stretched fiber before the tearing of the To temper filaments. The stretch properties of the inlet yarn remain obtained in the finished Stapelfasergarn substantially.

It is believed that other elastic fibers, e.g. Crimped fibers, can also be successfully processed using the teachings of the invention. Other fibers may have different polymer combinations, for example different nylon polymers, or different structures, such as e.g. B. biconstituent fibers. A biconstituent fiber is typically a fiber having a highly elastic (or "soft") core polymer, such as, for example, fiber. B. having a Lycra ^® elastomer, the "wings" of an inelastic ( "hard") polymer, which are applied during the spinning process than the longitudinal ribs. After spinning, the latent elasticity of the fiber can be activated by heat, which causes the soft core polymer to shrink significantly more than the hard wing polymer, causing the composite structure to spirally wind up and look like a screw thread. This fiber structure also has some "crimping" after spinning and stretching and before heat treatment, similar to the bicomponent fiber. Polymer pairs should be compatible so that they adhere to each other and can be spun together. For this they must have a similar thermal response and functional spin viscosity. Thus, useful pairs are usually chemically similar or have some specific interaction with each other. Common bicomponents are two polyesters, two nylons, etc., while the biconstituents z. B. 4GT / 4GT-4GO (HYTREL® ^®) and Nylon / PEBAX ^®; Homopolymer / block copolymer pairs are those in which one block of the copolymer is the same as the homopolymer. Ratios may vary considerably, but are generally limited to a range between 80/20 and 20/80, preferably 70/30 to 30/70. Other conventional crimping fibers, such as. As the crimped by nozzles, Zahnradkräuseler, Stauchkammerkräuseler and the like fibers could also be converted by application of the method according to the invention in a staple fiber yarn.

It is therefore obvious that according to the present Invention Process for stretch breaking continuous fibers Filaments have been provided to discontinuous fibers To form filaments and to compress these fibers into yarns, which fully achieve the goals and benefits outlined above. Although the invention is in connection with a specific embodiment been described, but it is clear that many alternatives, modifications and variants for the person skilled in the art will be apparent. Accordingly The invention is intended to all these alternatives, modifications and Variants that exist within the fundamental thought and the general Scope of the appended claims are.

Claims (30)

Tear drawing process for producing a staple yarn from a fiber having filaments and fed in a continuous operation, the method comprising: Tearing the Filaments in a first break zone L1 by raising a fiber velocity within a first break zone length a first speed ratio D1 that is greater than or equal to is equal to 2; Tear the filaments in a second breaking zone in the flow direction behind the first break zone by increasing the Fiber speed within a second break zone length L2 at a second speed ratio D2, the bigger one or is equal to 2, wherein D2 and D1 have a relationship (D2 - 1) / (D1 - 1) in FIG Range from 0.15 to 2.5, and L1 and L2 have a relationship Define L1 / L2 in the range of 0.2 to 0.6; and condense the fiber in a compression zone in the flow direction behind the second break zone to form a staple yarn. The method of claim 1, wherein the length L1 of the first break zone bigger or equals 50.8 cm (20.0 inches). The method of claim 2, wherein the relationship (D2-1) / (D1-1) is a Range of 0.2 to 2.0 and the relationship L2 / L1 an upper limit of less than 0.4. The method of claim 2, further comprising stretching the fiber in a draw zone in the flow direction before the first break zone by Increase has the fiber velocity within a predetermined stretch zone length. The method of claim 4, wherein in the method fed filaments belong to a group that is undrawn or partially stretched bicomponent filament structures and biconstituent filament structures having. The method of claim 4, further comprising the feed from additional Fiber in the process in the flow direction in front of a zone that has selected from the group is that from the first breaking zone, the second break zone, a draw zone and the compression zone. The method of claim 6, wherein the feed from additional Fiber feeding the first additional fiber into the process at the inflow end of the first break zone and the feeding of a second additional fiber of continuous Filaments in the process at the inflow end of the compression zone comprises. The method of claim 2, further comprising annealing the fiber in an annealing zone by heating the fiber within a predetermined annealing zone length having. The method of claim 8, wherein in the method fed filaments partially stretched and fully stretched crimped structures exhibit. The method of claim 1, further comprising a step with passage of the fiber through a bore and creation of a spiral fluid flow path in the bore has to loosen loose filament ends and the loose Filament ends loose around a core of tightly gathered filaments to wrap. Yarn with a compressed chemical fiber from discontinuous Filaments of different lengths, where the filaments in the longitudinal direction of the yarn are swirled to maintain the unity of the yarn, wherein the middle length ("avg") of the filaments greater than 15.24 cm (6 inches), and wherein the fiber has a filament length distribution has in the 5% to less than 15% of the filaments a length of have more than 1.5 avg. Yarn according to claim 11, wherein the fiber has a filament length distribution has in the 5% to less than 15% of the filaments a length of less than 0.5 avg. Yarn according to claim 11, further comprising continuous Having filaments in the longitudinal direction of the yarn with the discontinuous filaments are swirled. The yarn of claim 13, wherein the continuous filaments comprise elastic filaments having an elongation at break of greater than about 100% and an elastic recovery of at least 30% from an elongation of 50%. Yarn according to claim 11, wherein the continuous Filaments less than 10% elongation at break exhibit. Yarn according to claim 11, wherein at least 1% of the discontinuous Filaments in the yarn after thread count a fiber with a coefficient of friction between filaments of 0.1 or less. Yarn according to claim 11, wherein at least 1% of the yarn has a fluoropolymer according to thread count or 30% of a bicomponent yarn a first component of 2GT polyester and a second component made of 3GT polyester. Yarn according to claim 11, wherein the fiber is in the yarn have two fibers with visually distinct differences, the with mere Eye are recognizable. Yarn according to claim 18, wherein the differences are one Include difference in colors and shape of a multi-colored yarn, the colors of the fibers (with the exception of neutral colors) a Have brightness of more than 90% and the colors of the fibers have a color difference of at least 2.0 CIELAB units, the brightness and color differences being in accordance with standard E-284 of the ASTM Committee E12 are measured. Yarn according to claim 11, wherein at least 1% of the discontinuous Filaments in Denier yarn with a filament filament a latent elasticity of 30% or more. Apparatus for stretch-stretching a fiber comprising a first breaking zone ( 34 ), a second break zone ( 36 ) and a compression zone ( 38 ) having. wherein the first break zone has a length L1, the second break zone has a length L2 and 0.6 L1 ≥ L2 ≥ 0.2 L1 applies. Apparatus according to claim 21, wherein the compression zone comprises a turbulence jet ( 83 ), a single fluid jet, a plurality of fluid jets, a real twisting device, an interchangeable twisting device, an adhesive applicator or a bumping device. Apparatus according to claim 21, further comprising a draw zone ( 124 ) having. The device of claim 23, wherein the draw zone how an annealing zone works. Apparatus according to claim 21, further comprising a draw zone ( 144 ) between the second break zone ( 36 ) and the compression zone ( 38 ) or between the first break zone ( 34 ) and the second break zone ( 36 ) having. Apparatus according to claim 21, wherein the path of the Fiber arranged foldable by one or more functional zones is, so that, if a path vector in a first function zone end to end with a path vector in a following one Function zone is placed, an included angle between 45 degrees and 180 degrees is defined. Apparatus according to claim 21, wherein the apparatus comprises a first fiber feed upstream of the draw zone (Fig. 124 . 402 ) and a second fiber feed behind the draw zone and before the first break zone (FIG. 34 . 408 ) having. Apparatus according to claim 27, further comprising a third fiber feed ( 421 ) behind the second break zone ( 36 . 412 ) and before the compression zone ( 38 . 416 ) having. Apparatus according to claim 21, wherein the apparatus comprises a first fiber feed upstream of the draw zone (Fig. 124 ) and a second fiber feed ( 31a ) at the end of the drain ( 300 ) of the draw zone ( 144 ) having. Apparatus according to claim 29, further comprising a third fiber feed ( 31a ) at the end of the drain ( 300 ) of the draw zone ( 144 ) having.