DE60029441T2 - THREAD BUNDLE AND METHOD FOR THE PRODUCTION THEREOF - Google Patents

Description

AREA OF INVENTION

The The present invention relates to a thread and raw cotton materials and objects that be prepared therewith and method for producing such a Thread, raw cotton or fabric.

GENERAL STATE OF THE ART

The Production of spreadable continuous filament yarns with mechanical ripples and Process leading to uniform Spreading the filaments are used, for example, in the U.S. Pat. Nos. 3,730,824 and 3,952,134. Besides that is a curled thread band known, by a spreading device guided has been. Such thread bands are for the production of raw cotton materials useful as fiber filling for items such as Pillows, sleeping bags etc. can be used. Such expandable threads with mechanical crimping are with regard to their simplified processing requirements for Producing useful Objects and regarding the relative strength of raw cotton materials, those from such threads produced compared to conventional raw cotton materials, made of mechanically curled, Carded staple fibers are produced, particularly advantageous. Mechanically curly Threads and However, raw cotton materials made therefrom suffer under a restricted Softness, bulk and other aesthetic properties, which can be obtained.

Besides that is the use of three-dimensional crimped staple fibers in the state Technically well known. There are several lending methods a three-dimensional structure representing the technologies of asymmetric Quenching, the processing of continuous volume filaments (bulk continuous filament = BCF), the conjugate spinning of two Polymers that differ only in the molecular chain length, and the Bicomponent spinning of two different polymers or Copolymers, as in US Pat. No. 5,723,215, US Pat No. 3671379 and Japanese Patent JP61-32404 (B2).

US Patent No. 5683811 discloses bicomponent polyester fibers having a spiral crimp. Such polyester fibers can used in the manufacture of pillows and other stuffed objects become.

Regarding mechanical Ruffled Fibers and threads are three-dimensionally curled Staple fibers and articles known that are made to certain benefits such as a higher bulk, Softness, improved curl recovery, a higher one Provide incentive to buy and better compressibility. The Processing of these three-dimensional crimped staple fibers is due the softness and silkiness that partly impose the rippling structure is, but often difficult. Raw cotton materials made from such Fibers are also deficient in that they are often weak and easily destroyed become.

consequently There is a need in the art for obtaining a method for the manufacture and handling of three-dimensional crimped fibers in the manufacture of a thread that can be spread to Raw cotton materials for use in items such as sleeping bags, down comforters, To make comforters and pillows.

SUMMARY THE INVENTION

Corresponding this need is in accordance with the present Invention a three-dimensionally crimped spreadable continuous Filament yarn tape according to claim 1 provided. battings and objects, those from the three-dimensional ruffled Spreadable continuous filament thread band are one another aspect of the invention.

Further Objects, features and advantages of the invention will become apparent from the following detailed Description visible.

SUMMARY THE DRAWINGS

1 Fig. 12 is a schematic diagram showing a spinning and drawing method of a bicomponent thread according to the present invention.

2 is a schematic representation of a suture spreading method according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention overcomes the problems associated with the prior art by producing a three-dimensional crimped filament by means of a low cohesion banding process and a ribbon stacking process which provides low cohesion between individual constituent ribbons, thereby causing the combined filament ribbon is processed by spreading as an integral unit. A thread made in this way can be divided into its component bands by the thickness of the stack. In addition, the thread can still be processed by the spreading device as if it were only a single thread band. Consequently, it is possible that each thread band is spread uniformly over the width of the spreader.

As used in this specification, the term "curl" refers to the waviness or the volume of the fiber. A "three-dimensional curl" therefore refers on the volume or waviness of a fiber in three dimensions, compared with, for example, a two-dimensional zigzag crimp a mechanical ripple. A three-dimensional rippling has been described in the art for which various terms are used which, for example, are the spiral or helical crimp, Omega-crimp, three-dimensional random ripple etc. include. Three-dimensional ruffled Fibers are also in the art often referred to fiber bundles and Technologies for processing continuous volume filaments been described. Method of obtaining a three-dimensional ripple have also been described. For example, US Pat. 4618531 a method of making bundles or a randomly arranged, entangled, spiraling ruffled Polyester fiberfill. US Patent No. 5723215 describes a process for producing bicomponent polyester fibers with spiral or helical Crimp.

A "thread band" or "thread" or "strand band" refers to a big Strand of continuously produced filaments, in a loose, strand-like Form are summarized. The thread band of the present invention includes bicomponent filaments containing at least two polymers. Exemplary polymers for The thread ribbon of the present invention includes but is not limited Homopolymers, copolymers and terpolymers of monomers, the be formed in any type of melt-spinnable polymers can. Such melt-spinnable polymers are polyesters such as polyethylene terephthalate (PET), Polybutylene terephthalate (PBT or 4GT), polytrimethylene terephthalate (PTT or 3GT), polypropylene terephthalate and polyethylene naphthalate (PEN); and polyolefins such as polypropylene and polyethylene (PE); and Combinations thereof, including Bicomponent polyester fibers made from PET and PTT. Process for the preparation of homopolymers, copolymers and terpolymers, which in the present invention are in the state of Technique known and can the Use of catalysts, cocatalysts and / or chain branchers to give the copolymers and terpolymers according to the prior art To form technology.

The Polymers and resulting fibers used in the present invention can be used conventional Include additives that during the Polymerization or added to the polymer formed, and can contribute to the improvement of the polymer or fiber properties. Examples of these additives are antistatic agents, antioxidants, antimicrobials, refractory agents, dyes, light stabilizers, Polymerization catalysts and auxiliaries, adhesion catalysts, Anti-glare agents such as titanium dioxide, matting agents, organic phosphates and combinations thereof. Other additives, for example, during the Spinning and / or drawing process can be applied to fibers have antistatic agents, lubricants, adhesion catalysts, antioxidants, antimicrobials, refractory agents, lubricants and combinations of it. About that can out such additives during various steps of the method according to the state of Technique added become.

From particular value in the production of synthetic fiber filling products is the application of a lubricant, as in the prior art known. The lubricant provides the fiber or the raw cotton a silky, downy-like contact aesthetics ready and possible the fibers in the final finished article during use without matting move past each other. All suitable lubricants like silicone oils, preferably polyaminosiloxanes to be used. Antistatic agents and lubricants that are on The fiber applied are due to the support that she while fiber processing, also of particular importance. The antistatic agents can used to prevent the generation of static noise on the thread spreading device, and can be applied to the fibers before or after drawing.

The Fibers used in the present invention may further be used have any cross-sectional shape. The cross-sectional shapes can accordingly The state of the art, for example, round, oval, dreiflügelige forms with a larger number symmetrical or asymmetrical wing, a dog bone shape and hollow fibers with multiple openings or gaps, preferably having from about 1 to about 10 orifices. In a embodiment According to the invention, the fibers have a round cross-section with three Gaps on.

The fibers in the thread ribbon comprise bicomponent fibers of a first component selected from poly (ethylene terephthalate) and copolymers thereof and a second component, which is selected from poly (trimethylene terephthalate) and copolymers thereof, wherein the two components are present in a weight ratio of from about 95: 5 to about 5:95, preferably from about 70:30 to about 30:70. The cross-section of the bicomponent fibers may be a side-by-side or eccentric sheath / core. When a copolymer of poly (ethylene terephthalate) or poly (trimethylene terephthalate) is used, the comonomer of linear, cyclic and branched aliphatic dicarboxylic acids having 4 to 12 carbon atoms (for example, butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid and 1,4-cyclohexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid having 8 to 12 carbon atoms (for example, isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic and branched aliphatic diols having 3 to 8 carbon atoms (for example, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1 , 3-propanediol, 2-methyl-1,3-propanediol and 1,4-cyclohexanediol); and aliphatic and araliphatic ether glycols having 4 to 10 carbon atoms (for example, hydroquinone bis (2-hydroxyethyl) ether or a poly (ethylene ether) glycol having a molecular weight below about 460, including diethylene ether glycol). Isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propanediol and 1,4-budanediol are preferred because they are readily available commercially and inexpensively. Isophthalic acid is more preferred because copolyesters derived therefrom decolor less than copolyesters made with any other comonomer. When a copolymer of poly (trimethylene terephthalate) is used, the comonomer is preferably isophthalic acid, wherein 5-sodiosulfoisophthalate can be used in minor amounts as a dye comonomer in each of the two polyester components.

The Yarn ribbon of the present invention can be used to provide a To produce raw cotton. As used herein, a "raw cotton" refers to a continuous one Filament thread band, which is about 4 or more times its original width on a thread spreading device has been spread and wound crosswise to several To form layers. Preferably, the raw cotton one to five layers of the continuous filament thread band. The raw cotton is afterwards as fiber filling for items like Pillows, sleeping bags, Upholstery, blankets and insulating garments or objects used.

The Method of making the three-dimensional crimped continuous filament spreader of the present invention includes first Making fibers with the ability to create a three-dimensional Crimp structure too form. This can be done by any known means, including, but not limited on asymmetric quenching, processing of continuous Bulk filaments (BCF), conjugate spinning of two polymers that are differ only in molecular chain length, and Bicomponent spins of two different polymers or copolymers. Preferably, the filaments are spun with the capability of being a three-dimensional ripple and then pulled to achieve molecular alignment, which the ripples forms or causes the ripples to form.

One Example of making a fiber with a three-dimensional crimp has the following procedure: extruding bicomponent polymers through a capillary, spinning the extruded polymers to one Filament, around a fiber with two different woven alignment planes to form, and pulling the fiber and releasing the tension, so that the three-dimensional rippling forms.

One second method for producing a three-dimensional crimped Fiber refers to the spinning of a polymer through a capillary and contacting the polymer stream directly with a cooling stream, to form a filament, so that the formed in this way Filament due to the differential cooling rates through the Fiber over its diameter has a spun alignment gradient. The so-called "asymmetric Quenching "can carried out by known methods become. For example, asymmetric quenching can be judging an air jet against a capillary. As alternative can the filaments on one side with a continuously renewed Water layer are brought into contact to the desired three-dimensional ripple to create. After asymmetric quenching, the filament becomes pulled and the tension is solved in such a way that is three-dimensional Ripples form.

Furthermore can the methods of making a three-dimensional crimp be carried out in other ways, which in the state of Technics are known. Furthermore can combinations used by two or more of the above-mentioned technologies become. For example, the use of fibers with different Cross sections to the inclusion of one or more gaps or contribute to the existence of an incomplete scale. This can then the three-dimensional crimp structure provide or highlight the fibers, as well as other useful ones Provide properties.

Other methods of making a three Dimensional crimping are known in the art and / or described in references such as Polyester Fibers - Chemistry and Technology, Hermann Ludwig, Wiley-Interscience, 1964. Any of these technologies can be used to impart the three-dimensional crimp structure to the fiber.

As soon as the fibers with the ability for forming a three-dimensional crimping structure are, the fibers are grouped to form several separate strands. Any number of separate strands may be made from the fibers the three-dimensional rippling getting produced. There should be at least two strands, preferably 2 to 20 strands and most preferably 2 to 10 strands. These strands will be then subjected to a low cohesion threading process.

The Thread production process "with low cohesion "includes the simultaneous Pulling the separate strands under heat, to flat tapes too form, cooling the bands, to prevent further pulling, continuous stacking of the individual bands on top of each other and squeezing of the band. The tape can be used in any compression device pressed together become. Preferably, the tape passes through the nip of a pair compressed in the same direction rotating rollers. This stacking poses a low band-to-band cohesion ready without the tapes inextricably linked together. This stacking can be done in be executed in any way, the width of the completed stack essentially the width of each of the before independent bands equivalent. In addition to providing a low cohesion level away the squeezing also excess water from the band. A lubricant may be added after and / or before the compression step applied topically.

After this the flat bands pulled, stacked and squeezed and / or drained are, the three-dimensional rippling structure is formed or highlighted. For example, the three-dimensional crimp can for bicomponent filaments and asymmetrically ruffled Filaments spontaneously form after the tension of the thread band has been reduced or removed. On the other hand, the three-dimensional rippling for example with BCF fibers earlier form in the thread manufacturing process, wherein the reduction or removal of the voltage to highlight the already formed 3D Ripple leads.

To the crimp formation can the filaments are treated to cure the crimp. To the Example are the filaments for spontaneously formed three-dimensional crimping thread ribbons in usually heated in a continuous operation furnace to to break down the shrinkage stress, to cure the curl by heat and optionally the curing reaction to complete the lubricant. The tapes are then set to below cooled the glass transition temperature of the polymer so that the crimp made permanent and in a transport / storage container for transport is packaged to the thread spreading process. Other methods for permanent hardships the ripple are known in the art and can be applied.

According to the present Invention provides a "thread manufacturing process with low cohesion ", consequently, a threadline integrity is which is appropriate to packaging and introduction in one tow spreader as a subsequent processing step to allow however, that allows the thread band easily deregistered into individual filaments on the Fadenspreizgerät becomes. As used herein, the term "deregistering" refers to the opening of a Thread continuous ruffled Filaments, leaving the crimp structure in each filament with that of adjacent filaments not is more synchronized. As a rule, the deregistration follows a spreading step, in which the width of the thread band around the 4- is increased to 10 times that of the incoming thread band, if the tape over the width of the spreading device and along the length the band is spread substantially uniformly while it is passed through the spreading device becomes.

During the Method of making the three-dimensional crimped The expandable continuous filament of the present invention can be Filaments or fibers, as stated above, with any a number of finishing agents. In a preferred embodiment The filaments are lubricated on the drawing machine coated to make the filaments soft and smooth. Preferably the lubricant is a silicone oil. In yet another preferred embodiment, the filaments become treated with an antistatic finishing on the drawing machine, to the generation of static disturbances on the thread spreading device to eliminate.

The Lubricant is preferably applied after drawing but before thermosetting. The Thermosetting can then cure the lubricant and tie it to the fiber. After this step can be an antistatic Agents are applied.

It is further appreciated that additional method steps may be readily added and such steps are included in the scope of the appended claims rich considered invention. Further, the product made from such a process falls within the scope of the present invention.

The The following description refers to the figures as examples for this, like the process of making the three-dimensional crimped spreadable continuous filament thread of the present Invention executed can be.

In 1 Only the minimal essential operations for producing a spreadable bicomponent yarn are described, which relate to a spinning and drawing process for bicomponent yarns.

In 1 For example, two separate polymers are spun simultaneously through each spinneret capillary in a manner well known in the art for making bicomponent fibers by first passing the polymers through a device 1 which is designed to be any polymer to the entrance of each capillary on the spinneret 2 to distribute.

The polymers are then extruded through the spinneret, quenched with a suitable medium, usually conditioned air, and wrapped around one or more gussets 3 and 4 drawn. The fibers thus produced from one or more spinnerets are then stored in a suitable collection container 5 collected and transported to the separate drawing step.

In the drawing step, a plurality of spun strands from the separate containers, through 6 . 7 . 8th and 9 are combined, and optionally separated, to form a plurality of at least two separate strands, preferably two to twenty, most preferably two to ten separate strands. In the most preferred embodiment, four or more separate strands are made. These strands are then separated and simultaneously between a first set of rolls 10 and a second set of rollers 11 which operates at a surface speed of 2.5 to 5 times, preferably 3.0 to 3.5 times, that of the first set. The drawing temperature is determined either by the use of heated rolls or, as in 1 represented by the use of liquid sprays 12 with the first series of sprays operating at a controlled temperature of about 90 ° C to about 99 ° C (194 ° F to 210 ° F), whereas the last sprays are between about 15 ° C and about 70 ° C (59th to 210 ° F) ° F to 158 ° F), preferably about 20 ° C to about 40 ° C (68 ° F to 104 ° F). Alternatively, the feed rollers 10 be controlled at the higher temperatures while the drawing rollers 11 be controlled at the lower temperature.

After the drawing rolls, the separate bands are from a pair of opposing rolls 14 pulled through a unit for stacking the bands, which in 1 as the angle bars 13 is shown. This stacking may be carried out in any desired manner and is preferably carried out such that the width of the completed stack substantially corresponds to the width of each of the previously independent bands.

The stacked tapes are then placed under low tension on a conveyor belt 15 Put the fiber through an oven 16 leads. The oven is intended to remove the shrinkage from the fiber and cure any siliconized finish that can be applied to the fiber by any of several known means prior to settling on the oven conveyor belt. Typically, the oven temperature is from about 100 ° C to about 200 ° C (212 ° F to about 392 ° F), preferably from about 140 ° C to about 180 ° C (284 ° F to about 356 ° F). The residence time within the heated areas of the furnace is usually in the range of 5 to 20 minutes, preferably 7 to 15 minutes. The fiber is then passed through a cooling section which is operated for about 1 to 5 minutes, preferably 1 to 3 minutes at ambient temperature. After the oven, we put the fiber in a suitable storage / transport container 17 arranged for transport to the yarn spreading device.

The following description belongs to 2 , which describes an example of the thread spreading method within the scope of the present invention. In 2 becomes the thread band 18 consisting of helically crimped fibers, from the storage / transport container 19 taken and by an anti-wrinkle guide 20 pulled, which serves to remove twisting and wrinkles from the tape.

The thread off 2 is then through a series of guides 21 . 22 and 23 pulled before being fed into the nip of a driven pair of opposed cylindrical rollers 24 and 25 is produced. The first of these rollers 24 is metallic and has a helically grooved surface. The second roll is of a composition of a rubber-like material and has a smooth surface. From this pair of rollers, the thread is guided into the nip, that of a second pair of opposing rollers 26 and 27 is generated in a substantially identical manner as each of the roles 24 and 25 are constructed and driven at a higher speed than that of the first pair. The speed differential associated with the grooved roll surfaces is, causes a differential stretching and tensioning of the filaments and serves the deregistration of the thread. These different surfaces and compositions of the rolls can be modified provided that a differential tensioning effect is achieved, as described, for example, in US Pat. No. 3,423,795.

The deregistered thread is then passed through the nip of a driven pair of opposed smooth rolls 28 and 29 which serves to isolate the high voltage deregistration process from the following low stress spreading process.

From the insulation rollers, the thread can be passed through a spreading. For example, the spreading portion may be an air-spreading jet 30 similar to that described by Watson in U.S. Patent No. 3,423,795, and an opposed set of driven metallic rollers 31 and 32 contain. The air flowing through the spreading jet causes the filaments within the thread ribbon to migrate outwardly from the center line. From the first spreading section, the thread is passed through a second spreading section which forms an air spreading jet 33 and tension isolation rollers 34 and 35 includes. The spreading section 2 is essentially identical to section 1 with the exception that the air spreading jet and tension isolation rollers are longer. This increased length allows the thread band to be spread wider as it moves through the machine. After the second spreading section, the thread is passed through a third spreading section, which forms an air spreading jet 36 and tension isolation rollers 37 and 38 contains. Although this portion is substantially similar to the previous expansion portion, it is even wider, allowing the thread to spread further. The thread, which is guided out of the third expansion section, is guided into a fourth expansion section, which passes through an air-spreading housing 39 and rolling 40 and 41 which are similar to the previous parts but are again wider than the previous section.

From this spreading section, the thread is passed through a nip passing through a pair of transverse winding rolls 42 and 43 is created, which at the same time the spread thread from the roller 41 Pull while being perpendicular over a moving band 44 back and forth, creating a layered raw cotton continuous filaments 45 is formed. The cross-wound raw cotton may also be stretched by passing it through one or more sets of draw rolls to reduce and better control the weight per unit area. The raw cotton thus formed may at this point be collected on rolls, subjected to a resin binder application and rolled into pillows or subjected to any other processing step known to manufacturers of raw fiber cotton.

Of the three-dimensionally curled expandable continuous filament yarn of the present invention is useful in the production of raw cotton materials, which have a good bulkiness. In particular, the bulkiness, the three-dimensional crimp from the bicomponent thread of the present invention, superior to bulk power, which is known from two-dimensional mechanically crimped threads. The three-dimensional ruffled Thread also has other desirable ones Properties such as better compressibility, softness, increased filling power, strength and increased Heat up.

Further Most three-dimensional ruffled structures usually have Difficulty spreading and separating the fibers from each other, since the ripple in each fiber has many random contact points with other fibers. Consequently, defects in spreading of typical bicomponent filaments are open Sections on, which arise when a filament of a section of the tape adheres to an adjacent filament while the Band is splayed, causing a hole in the track next to the sticky Creates filaments. The three-dimensionally curled spreadable thread of the overcomes the present invention However, these difficulties stacked by the multitude of small ribbons what is the fiber cohesion over the Reduced band, with stacking providing coverage, leaving a defect in any band masked by the other bands becomes. About that In addition, by pulling the thread of several separate strands and subsequent stacking of the bands a sufficient cohesion across the band to a uniform spread to obtain. Accordingly, the three-dimensionally curled expandable threads capable of the present invention, evenly spread to become raw cotton materials with high bulk, better compressibility, Softness, elevated filling power, Strength and heat manufacture. About that In addition, this arrangement serves to minimize deposits, cracks and crossed Filaments that impede a good spread.

Claims (6)

Yarn ribbon comprising: a three-dimensionally crimped spreadable continuous filament, said ribbon comprising bicomponent fibers comprising: a first component comprising is selected from the group consisting of poly (ethylene terephthalate) and its copolymers, and a second component selected from the group consisting of poly (trimethylene terephthalate) and copolymers thereof, wherein the two components are in a weight ratio of 95: 5 are available until 5:95. The suture ribbon of claim 1, wherein the suture ribbon comprises helically crimped filaments. Yarn ribbon according to claim 1, wherein the two components in a weight ratio from between 70:30 to 30: 70 are present. Yarn ribbon according to claim 1, wherein the first component a copolymer of poly (ethylene terephthalate), wherein a comonomer, used for the preparation of the copolymer selected from the group consisting of made of isophthalic acid, Pentanedione acid, hexanedioic, 1,3-propanediol, and 1,4-butanediol. Raw cotton, the three-dimensionally curled comprises expandable continuous filament yarn tape according to claim 1. filled An article made from a three-dimensionally crimped, spreadable thread band Claim 1 is included.