EP1675980A1 - Yarn - Google Patents
YarnInfo
- Publication number
- EP1675980A1 EP1675980A1 EP03776527A EP03776527A EP1675980A1 EP 1675980 A1 EP1675980 A1 EP 1675980A1 EP 03776527 A EP03776527 A EP 03776527A EP 03776527 A EP03776527 A EP 03776527A EP 1675980 A1 EP1675980 A1 EP 1675980A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fiber
- copolymer
- yam
- filaments
- polymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
Definitions
- a simpler direct spinning process is also used wherein parallel continuous filaments are stretch-broken and drafted between input rolls and delivery rolls in what is sometimes called a stretch break zone or a draft cutting zone to form a sliver of discontinuous fibers which is thereafter twisted to form a spun yarn as disclosed, for example, in US 2,721,440 to New or US 2,784,458 to Preston.
- Such early processes were slow due to the inherent speed limitations of a true twisting device.
- Bunting et al in US 3,1 10,151 discloses consolidating staple fibers to make a yarn product using an entangling, or interlacing, jet device for entangling into yarn.
- Static removal devices are also placed adjacent the roll pairs that forward the filaments through the process.
- About 1.5-20% of the discontinuous filaments produced in the stretch-breaking zone exceeds 76 cm in length.
- the yarn axis is required to be vertical throughout the process.
- the resultant product is a consolidated yarn with excellent strength, generally higher than ring-spun yarns, which is slub-free and clean.
- Multiple stretch-break zones are taught in US 4,924,556 to Gilhaus for progressively reducing the discontinuous filament length for large denier tows which are built up from combining several low weight tows over tensioning guide bars and guiding members. In this way distortions of less than 4.5 can be run with low weight feed tows and production capacity remains high.
- the combined tows are drawn without breaking in a distortion and heating zone (zone I) at one horizontal level and then passed sequentially through one or more progressively shorter, stretch-breaking zones, (zones II-V) arranged horizontally in another level to conserve floor space.
- the stretch-breaking zones may comprise one or more "preliminary" breaking zones that progressively shorten the fibers, and one or more breaking zones that set the average fiber length and set the variability of fiber length (%CV).
- the sliver formed may be processed in an entwining mechanism (to facilitate subsequent handling), heat treated, and collected in a canister. It is expected that the sliver would be further processed, as in a spinning machine, to produce small denier yarns.
- a first preliminary breaking zone, zone II is at least 500 mm long and the filament lengths resulting from this zone have a "nearly normal distribution" of fiber lengths between a few millimeters and the length of zone II.
- the zone II length is an optimization between a longer length, which reduces the breaking forces, and a shorter length, which avoids floe breaks and improves operating conditions.
- a second preliminary breaking zone, zone III which is at least 200 mm and less than 1000 mm which is "considerably shorter" than zone II.
- zone IV which sets the average fiber length and appears shorter than zone III
- zone V which eliminates overly long fibers, sets the variations in fiber length (characterized by %CV), and appears shorter than zone IN.
- zone V the "breaking distortions" (believed to be speed ratios) are at least 2X those in zone IN.
- a horizontal in-line process for making a fasciated yarn from a tow of fibers is taught by Minorikawa et al in U.S. 4,667,463. The process involves drawing the tow over a heater in an elongated area having a narrow width, draft cutting the tow, and subjecting the draft cut fibers to an amendatory draft cutting step and a yarn formation step.
- the length of the zone in the amendatory draft cutting step is about 0.4 to 0.9 times the length of the draft cutting zone and the draw ratio for the amendatory draft cutting is at least 2.5x.
- the drawing preferably occurs in two stages to achieve a draw ratio of 90-99% of the maximum draw ratio and the drawn fiber is then heat treated.
- the yarn formation step uses a jet system for consolidating the fibers by creating wrapper fibers around the fiber core and wrapping them around the core fibers. Occasionally, apron bands are used in the amendatory draft cutting zone and yarn formation zone to regulate the peripheral fibers. The product is described in U.S.
- 4,356,690 to Minorikawa et al as being characterized by the fact that more than about 15% of the filaments in the yarn have a filament length of less than 0.5 times the average filament length of the yam and more than about 15% of the filaments in the yam have a filament length greater than 1.5 times the average filament length of the yam.
- the maximum output speed of the process making yams of 174 to 532 denier (30.5 to 10 cotton count) is 200 meters/minute (ex. 6) with most examples run at about 100 meters/minute.
- US 4, 118, 921 to Adams et al. discloses a zero twist, staple fiber yam of good strength, cleanness and uniformity produced from continuous filaments by a direct spinning process followed by entangling to a pin count of less than 50 millimeters. Filaments of less than 70 percent break elongation are stretch broken to fibers having an average length of 18 to 60 centimeters with at least 5 percent short fibers, at least 1.5 percent long fibers, and 50 to 93.5 percent fibers of lengths between 12.7 and 76 centimeters.
- a rupture conversion machine for rupture conversion of chemical fiber cables into chemical fiber strips has, for its pre- rupturing head and rupturing head in each case two driven transport cylinders, to which hydraulically loaded, freely rotatable pressure roller is assigned, between which the chemical fiber cable that is to be processed is conveyed in a force - locking manner.
- the circumferential speed of the second transport cylinder in the process direction is larger than that of the first transport cylinder and/or that the circumferential speed of the pressure roller in the clamping range between this and the second transport cylinder in the process direction is larger than in the clamping range between the pressure roller and the first transport cylinder.
- Applicants have developed a process that produces a small denier, discontinuous filament yam with filament lengths shorter than about 64 cm (25 in) that results in a high number of filament ends per inch from continuous filament feed ya .
- the new process operates at rates that make production of individual yams commercially feasible. The production rates greatly exceed those of ring spun staple yams that traditionally have a high number of filament ends per inch.
- the process permits operation in either a vertical or horizontal orientation without sacrificing mrmability.
- the process is adaptable to a variety of continuous filament yam polymers and for blending dissimilar continuous filament yams.
- the process utilizes at least two break zones for obtaining the preferred filament lengths in the final yam product having an average filament length greater than 6.0 inches and the speed ratio Dl of the first break zone and the speed ratio D2 of the second break zone should be at a level of at least 2.0.
- a relationship a relationship
- L2/L1 between the second break zone length L2 and the first break zone length LI is constrained to be in a range of 0.2 to 0.6 to achieve the desired overall filament lengths, length distribution, and good system operability.
- a consolidation zone for consolidating the discontinuous filaments in the yam and intermingling them by any of a variety of means to maintain unity of the yam.
- the process includes improvements to systems having one or more stretch break zones.
- One feature of the new process is based on the belief that it is important to arrange for some "double gripped" filaments throughout the stretch-break and drafting process. Double-gripped filaments are those that are long enough to span the distance between two roll sets for each stretch breaking and drafting zone. Double-gripped filaments provide some support for the other filaments so there is good cohesion of the filament bundle in each zone that aids runnability, especially when making low denier yams with few filaments. If low speed ratios are utilized in the break zones, this is believed to result in more long filaments that can serve as double-gripped filaments, but this requires more break zones to achieve a high overall speed ratio to improve productivity.
- speed ratio Dl of the first break zone being > 2.0 and the speed ratio D2 of the second break zone being > 2.0 should also preferably satisfy the following equation: (D2-1)/(D1-1)> 0.15 More preferably, the relationship should satisfy the following equation: (D2-l)/(Dl-l)> 0.15 and is ⁇ 2.5
- the zone length of the second zone is also constrained to be less than or equal to 0.4 times the first zone length.
- a separate zone is provided primarily for drafting the already broken filaments without further breaking.
- a draw zone is also utilized to draw the fiber without breaking filaments in a draw zone that precedes the break zones and can draw the fiber with or without the application of heat.
- an annealing zone is employed when desired to heat the fibers and control product features such as shrinkage. An annealing zone is most often part of the drawing zone, but may be applied at a variety of locations in the process.
- the process produces novel products by providing the opportunity to introduce a variety of fibers to the process in a way not previously disclosed to make a wide range of stretch broken yams. For instance, with a variety of different zones employed in the process, additional fiber can be introduced at different locations in the process to achieve unusual and novel results.
- Typical of such products are those that blend continuous filament yams with the discontinuous filament yams by introducing the continuous filament yams at a location downstream from the break and draft zones and upstream of the consolidation zone or zones.
- Other products employ polymeric materials with properties not envisioned for use in a stretch- breaking process, especially one with applicant's unique operating procedures.
- Such products include the following: - a ya comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yam to maintain the unity of the yam, wherein the average length, avg, of the filaments is greater than 6 inches (-15.24 cm), and the fiber has a filament length distribution characterized by the fact that 5% to less than 15% of the filaments have a length that is greater than 1.5avg.
- a yam comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yam to maintain the unity of the yam, wherein the average length of the filaments is greater than 6 inches (-15.24 cm), and wherein the fiber includes continuous filaments intermingled with the discontinuous filaments along the length of the yam, the continuous filaments having less than 10% elongation to break.
- a yarn comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yam to maintain the unity of the yam, wherein the average length of the filaments is greater than 6 inches (-15.24 cm), and wherein the fiber includes continuous filaments intermingled with the discontinuous filaments along the length of the yarn, the continuous filaments comprise elastic filaments having an elongation to break greater than about 100% and an elastic recovery of at least 30% from an extension of 50%.
- a yam comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yarn to maintain the unity of the yam, wherein the average length of the filaments is greater than 6 inches (-15.24 cm), wherein at least 1% of the discontinuous filaments in the yam by denier comprises a fiber having a filament-to-filament coefficient of friction of 0.1 or less.
- the low friction component is a fluoropolymer.
- a yam comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yarn to maintain the unity of the yam, wherein the average length, avg, of the filaments is greater than 6 inches( ⁇ 15.24 cm), and the fiber has a filament length distribution characterized by the fact that 5% to less than 15% of the filaments have a length that is greater than 1.5avg, and wherein the filament cross-section has a width and a plurality of thick portions connected by thin portions within the filament width, and the thin portions at the ends of the discontinuous filaments are severed so the thick portions are separated for a length of at least about three filament widths to thereby form split ends on the filaments.
- a yarn comprising a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yam to maintain the unity of the yam, wherein the average length, avg, of the filaments is greater than 6 inches( ⁇ 15.24 cm), and the fiber has a filament length distribution characterized by the fact that 5% to less than 15% of the filaments have a length that is greater than 1.5avg, and the fiber in the yam comprises two fibers that have visually distinct differences detectable by an unaided eye.
- the differences are a difference in color, the colors of the fibers excluding neutral colors having a lightness greater than 90%, and wherein the colors of the fibers have a color difference of at least 2.0 CEELAB units, the lightness and color difference measured according to ASTM committee E12, standard E-284, to form a multicolored yam.
- the fiber is a bicomponent yam comprising a first component of 2GT polyester and a second component of 3GT polyester. Different processes are disclosed for making some of the products just discussed.
- the processes involve managing the operation of the spinning machine, spinning at least 500 fibers at a spinning position, to simultaneously produce a plurality of products, having an individual lot size about 20 (-9.07 kg) to 200 (-90.72 kg) lbs, collected into a container, the lot size being smaller than a lot of the single large denier tow product; and providing at least one spinning position with a means for collecting tow from the at least one spinning position into a container making a low denier tow product.
- Various improvements to conventional stretch break processes are disclosed including: - gathering the loose filament ends in the break zone and adjacent the exit nip rolls and directing them toward the fiber core so the loose ends in all directions around the core are constrained to be within a distance from the center of the core of not greater than the distance of the center of the core from each respective end of the exit nip rolls for the break zone to minimize wrapping of the loose ends on the exit nip rolls.
- a further embodiment of this invention is a stretch-break process for producing a staple yam from fiber comprising filaments fed into a continuous operation by: breaking the filaments in a first break zone; breaking the filaments in a second break zone located downstream from the first break; and consolidating the fiber in a consolidation zone downstream from the second break zone to form a staple yam; wherein additional fiber is fed into the process upstream of a zone selected from the group consisting of the first break zone, the second break zone, and the consolidation zone. When a draft zone is used, additional fiber may also be fed into the process upstream of the draft zone.
- a further embodiment of this invention is a yam comprising a consolidated fiber of (a) discontinuous filaments of different lengths that have not been drawn and are intermingled along a length of the yam to maintain a unity of the yam, and (b) continuous filaments intermingled with the discontinuous filaments along the length of the yam; wherein the discontinuous filaments comprise materials selected from the group consisting of nylon, polyester, an aramid (a polymer derived for example from m- or/?-phenylenediamine and terephthaloyl chloride), a fluoropolymer, an acetate polymer or copolymer, an acrylic polymer or copolymer, polyacetal, an acrylate polymer or copolymer, polyacrylonitrile, a cellulose polymer, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), polyimide, a styrenic polymer or copoly
- a further embodiment of this invention is a yam comprising a consolidated fiber of (a) discontinuous filaments of different lengths that have been drawn and are intermingled along a length of the yam to maintain a unity of the yam, and (b) continuous filaments intermingled with the discontinuous filaments along the length of the yam; wherein the discontinuous filaments comprise materials selected from the group consisting of nylon, polyester, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), an ether/ester copolymer, an acrylic polymer or copolymer, polyacetal, poly(vinyl chloride), and mixtures of any two or more thereof; and wherein the continuous filaments comprise different materials selected from the group consisting of nylon, polyester, an aramid (a polymer derived for example from m- or/j-phenylenediamine and terephthaloyl chloride), a fluoropolymer, an acetate polymer
- a further embodiment of this invention is a yam comprising a consolidated fiber of (a) discontinuous filaments of different lengths that have been drawn and are intermingled along a length of the yam to maintain a unity of the yam, and (b) discontinuous filaments of different lengths that not have been drawn and are intermingled along a length of the yam to maintain a unity of the yam; wherein the discontinuous drawn filaments comprise materials selected from the group consisting of nylon, polyester, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), an ether/ester copolymer, an acrylic polymer or copolymer, polyacetal, poly( vinyl chloride), and mixtures of any two or more thereof; and wherein the discontinuous filaments that are not drawn comprise different materials selected from the group consisting of nylon, polyester, an aramid (a polymer derived for example from m- or -phenylenediamine and terephthalo
- Figure 1 is a schematic elevation view of a process line that includes a first and a second break zone and a consolidation zone.
- Figure 1 A is a close up of a roll set where the fiber path is an "omega" path especially useful with high strength fiber or fiber with a low coefficient of friction.
- Figure 2 is a schematic perspective view of filament ends and double gripped filaments in a fiber being stretch-broken between two sets of rolls.
- Figure 3 is a graph of a double gripped fiber ratio versus a total speed ratio for two cases of stretch breaking fibers using a simulation model.
- Figure 4 is a graph of a double gripped fiber ratio versus a speed ratio for a single case of two break zones for stretch breaking fibers using a simulation model.
- Figure 5 is a sensitivity plot of the information of Fig. 4 looking at variations in the fiber elongation to break, ei,.
- Figure 6 is a sensitivity plot of the information of Fig. 4 looking at variations in the length of break zone 2 compared to the length of zone 1.
- Figure 7 is a sensitivity plot of the information of Fig. 4 looking at variations in the total speed ratio for the two break zones.
- Figure 8 is a schematic elevation view of a process line that includes a draw zone, a first and a second break zone, and a consolidation zone where the draw zone may also function as an annealing zone.
- Figure 9 is a schematic elevation view of a process line that includes a draw zone, a first and a second break zone, a draft zone, and a consolidation zone.
- Fig. 10 shows the curves of Fig. 4 with the left vertical axis expanded and a right vertical axis added to compare the Fig. 4 curves with some actual test data.
- Figure 10 A is a plot of data from a designed test of operability for different values of Dl and D2 to collect optimum data for the plot of Fig. 10.
- Figure 11 is a schematic elevation view of a machine for practicing the process in Figures 1, 8, and 9 and variations thereof.
- Figure 12 is a perspective view of a swirl jet from Fig. 11 for swirling loose filaments around the fiber.
- Figure 13 is a schematic view of a piddling device for piddling feed fiber through a fiber distributing rotor and into an oscillating container.
- Figure 14 is a section view of the rotor of Figure 13.
- Figure 15 illustrates a plot of filament length distribution for an actual yam test and from a simulation of that test.
- Figures 16 and 17 illustrate a simulation of two comparative examples using only a single stretch-break zone and the fiber distribution that resulted, which falls outside of the limits of the invention.
- Figures 18 and 19 illustrate simulations of other operating conditions and the fiber distribution that resulted, which falls within the limits of the invention.
- Figure 20 shows the process schematic of Figure 9 where an additional feed fiber is introduced at the upstream end of the consolidation zone.
- Figure 21 shows the process schematic of Figure 9 where an additional feed fiber is introduced at the upstream end of the first break zone.
- Figure 22 shows the process schematic of Figure 9 where a first additional feed fiber is introduced at the upstream end of the first break zone, and a second additional feed fiber is introduced at the upstream end of the consolidation zone.
- Figure 23 is a schematic elevation view of the process line of Fig. 9 that includes an annealing zone after the consolidation zone.
- Figure 24 shows a photomicrograph of a stretch-broken filament that has split ends.
- Figure 25 is a cross section of the filament of Fig. 24.
- Figure 26 shows a perspective view of an interlace jet for consolidating the fiber.
- Figure 27 shows a cross section 26-26 through the jet of Fig. 26.
- Figure 28 shows a pneumatic torsion element for consolidating the fiber, where the left half of the figure is in section view taken along the fiber path and the right half is in plan view.
- Figure 29 shows an isometric view of a prior art staple spinning machine to provide large denier tow product feeding a conventional staple yam process.
- Figure 30 shows an isometric view of a staple spinning machine modified to provide both low denier and high denier tow product.
- Figure 31 shows an isometric view of a staple spinning machine modified to provide low denier tow product from individual positions feeding a stretch break yam process.
- Figure 32 shows a diagrammatic view of a process line having a folded path that saves floor space.
- Figures 33 A, B, and C show diagrammatic views of functional zone path vectors for the zones of Fig.
- Figures 34A and 34B shows cross section views of a trough that gathers loose filaments ends toward the fiber core before the fiber goes through a nip roll.
- Figure 35 shows a typical plot of yam strength versus the distance between two nozzles of a consolidation device for different average filament lengths.
- Figure 1 shows a schematic of a preferred process for stretch breaking a fiber 30 to form a yarn 32 using at least a first break zone 34 and a second break zone 36 and a consolidation zone 38.
- Fiber 30, which may comprise several fibers 30a, 30b, and 30c is fed into the process at a process upstream end 40 through a first set of rolls 42, comprising rolls 44, 46, and 48.
- Roll 46 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and rolls 44 and 48 are driven by their contact with roll 46.
- the fiber 30 is fed to a second set of rolls 50, thereby defining the first break zone 34 between roll sets 42 and 50.
- Roll set 50 comprises roll 52, roll 54 and roll 56.
- Roll 54 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and rolls 52 and 56 are driven by their contact with roll 54.
- the first break zone 34 has a length LI between the nip of roll 46 and roll 48, which lies on line 58 between their centers, and the nip of roll 52 and 54, which lies on line 60 between their centers.
- the fiber speed is increased within the first break zone 34 by driving the fiber at a first speed SI with roll set 42 and driving it at a second speed S2, higher than speed SI, with roll set 50.
- the fiber speed and roll surface speed at the driven roll 46 are the same, and the fiber speed and roll surface speed at the driven roll 54 are the same.
- Increasing the speed of the fiber within first break zone 34 causes filaments in the fiber longer than the length LI to be stretched until the break elongation of the fiber is exceeded and the filaments gripped by both roll sets will be broken.
- the speed ratio Dl should be such that the maximum imposed strain on the filaments exceeds the break elongation of the fiber, which is a known requirement for stretch breaking of fiber.
- the fiber fed into the process is a fiber composed entirely of continuous filaments, and the above conditions for breaking filaments are met, all the filaments will be broken in the first break zone.
- the now discontinuous filament fiber may also be drafted in first break zone 34 to reduce the denier of the fiber as the speed of the fiber continues increasing until it reaches the speed S2 of the roll set 50.
- the fiber 30 is fed to a third set of rolls 62, thereby defining the second break zone 36 between roll sets 50 and 62.
- Roll set 62 comprises roll 64, roll 66 and roll 68.
- Roll 66 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and rolls 64 and 68 are driven by their contact with roll 66.
- the second break zone 36 has a length L2 between the nip of roll 54 and roll 56, which lies on line 70 between their centers, and the nip of roll 64 and 66, which lies on line 72 between their centers.
- the fiber speed is increased within the second break zone 36 by driving the fiber at the second speed S2 with roll set 50 and driving it at a third speed S3, higher than speed S2, with roll set 62.
- the speed ratio D2 should be such that the maximum imposed strain on the doubly gripped filaments exceeds the break elongation of the fiber, which is a known requirement for stretch-breaking of fiber having discontinuous filaments.
- the discontinuous filament fiber may also be drafted in the second break zone 36 to reduce the denier of the fiber as the speed of the fiber continues increasing until it reaches the speed S3 of the roll set 62.
- the fiber 30 is fed to a fourth set of rolls 74, thereby defining the consolidation zone 38 between roll sets 62 and 74.
- Roll set 74 comprises roll 76 and roll 78.
- Roll 76 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and roll 78 is driven by its contact with roll 76.
- the consolidation zone 38 has a length L3 between the nip of roll 66 and roll 68, which lies on line 80 between their centers, and the nip of roll 76 and 78, which lies on line 82 between their centers.
- the consolidation zone includes some means of consolidation, such as an interlace jet 83 shown between the roll sets 62 and 74.
- the fiber speed can be decreased slightly within the consolidation zone 38 by driving the fiber at the third speed S3 with roll set 62 and driving it at a fourth lower speed S4 with roll set 74.
- the comparison in speeds of the fiber at the two roll sets, 62 and 74, defines a speed ratio D3 S4/S3.
- D3 S4/S3.
- the interlace jet interconnects the filaments by entangling them with one another to form a staple yam and in doing so it can slightly shorten the length of the fiber as the yam is formed which accounts for the decreased speed in this particular consolidation zone.
- the fiber speed within the consolidation zone 38 may be increased by driving the fiber at the third speed S3 with roll set 62 and driving it at a fourth speed S4, higher than speed S3, with roll set 74.
- some drafting would occur in the consolidation zone 38 as the speed of the fiber continues increasing until it reaches the speed S4 of the roll set 74.
- the roll sets 42, 50, and 62 have been shown as three roll sets with the fiber passing substantially "straight" through the roll sets there being a slight wrapping around the rolls. This frequently is a simple effective way to provide good gripping of the fiber and have a simple fiber thread up path for the process. It is believed to be important to control static charge build up on the fibers as they are broken in the break zones 34 and 36.
- Free fiber ends created by filament breaking tend to extend from the surface of the fiber repelled by static forces as the filaments slide one on the other. These extending statically charged free ends tend to wrap on the nip rolls, especially in roll sets 50 and 62, thereby creating machine stoppages. It is believed to be beneficial to contact the fiber with an electrically conductive roll surface to dissipate the static charge. This can be done by making at least one of the rolls of the nip rolls, gripping the unconsolidated discontinuous fiber, a metallic conductive surface, for instance, rolls 44, 48, 52, 56, 64, and 68. Roll 76 may also be a conductive surface, but this is not as important since the free ends are consolidated with the fiber core when passing through this nip.
- roll 44 may not need to be metallic since the fiber at this point is still a bundle of continuous filaments and no free ends are present.
- roll 48 due to the dynamic filament breaking taking place in break zone 34, there may be some free ends present so having roll 48 with a conductive surface may be beneficial.
- rolls 52 and 56 are metallic surfaces contacting a non-conductive, resilient, elastomer surface on roll 54.
- the path of the discontinuous filament fiber at the entrance and exit of the roll set is also important when contacting a roll set, such as 50, to arrange the path of the discontinuous filament fiber at the entrance and exit of the roll set to first contact the fiber to an electrically conductive nip roll before contacting it to an electrically non-conductive nip roll and to only separate the fiber from an electrically non-conductive nip roll by first separating the fiber from the electrically non-conductive nip roll before separating it from an electrically conductive nip roll to thereby minimize static buildup in the fiber as it passes through the nip rolls.
- the first surface contacted by the fiber entering a nip set should be a conductive surface and the last surface contacted by the fiber exiting a nip set should be a conductive surface.
- the rolls 52 and 56 are angularly located around the center of roll 54 so a wrap angle 51 of about 5 degrees or more occurs on roll 52 before the fiber makes contact with roll 54, and a wrap angle 53 of about 5 degrees or more occurs on roll 56 after the fiber breaks contact with roll 54. This situation is repeated for roll set 62.
- Figure 1 A shows another way of threading up the roll sets called an "omega" wrap, referring to roll set 42.
- the fiber is fed in under roll 44, rather than over the top, and is then wrapped around roll 44, roll 46, and under roll 48. This increases the surface contact substantially between the fiber and the rolls 44, 46, and 48.
- This is a useful technique if the fiber demands good frictional engagement with the roll set to avoid fiber slippage over the roll set. Conditions when this is required may be when the fiber is a high strength fiber and a large breaking force is required to be developed by the roll sets, or when the fiber has a very low coefficient of friction between filaments in the fiber and between the fiber and the roll surface.
- Fluoropolymer fiber having a coefficient of static friction between filaments of less than or equal to about 0.1, would be such a fiber that would benefit from an "omega" wrap when processing it by stretch breaking.
- the roll 48 With this omega wrap, the roll 48 has a conductive surface and has a large wrap angle 55 of greater than 90 degrees with the fiber after it has broken contact with roll 46 that has a non-conductive elastomer surface. This will effectively dissipate the static generated as the fiber separates from the elastomer surface as discussed above.
- fiber means an elongated textile material comprising one or multiple ends or bundles of the same or different material comprising multiple filaments that can be discontinuous or continuous and are unconsolidated, thereby retaining significant mobility between the filaments.
- Filaments are single units of continuous or discontinuous (i.e. finite length) material.
- the term yam or staple yam means an elongated textile material that comprises a consolidated fiber including discontinuous filaments, where the consolidated fiber has a substantial tensile strength and unity along the length of the yam and filament mobility is present, but limited. Continuous filaments may also be present in the yam or staple yam.
- the feed fiber for the above described process may come from a wound package of fiber or may come from a container of piddled fiber from which the fiber may be freely withdrawn as will be discussed below.
- the consolidated yam may be wound into a package or piddled into a container for transfer to another process or for shipping; or passed on to other machine elements for further processing.
- a break zone and breaking the filaments refers to increasing the speed of fiber comprising continuous or discontinuous filaments in a zone for the primary purpose of breaking fibers in a way that more than 20% and preferably more than 40% of the filaments are broken. When continuous filaments or discontinuous filaments longer than the break zone are fed into the break zone 100% of the filaments are broken.
- a break zone and breaking the filaments may also include cutting or weakening all or a portion of the continuous or long discontinuous filaments such as with a cut-converter device or breaker bar device (as described in U.S. 2,721,440 to New or U.S.
- the first break zone and second break zone means two distinct break zones with the second one occurring after the first one in the progression of the fiber through the two break zones. It is intended that the second break zone does not have to be right next to the first break zone and the first break zone does not have to be the first zone in a process.
- the feed fiber entering the first break zone can be continuous filament fiber, a discontinuous fiber of long length filaments that are to be broken in the first break zone, or a combination of continuous and discontinuous filament fiber.
- consolidating includes interconnecting the filaments in the fiber by any means of consolidating, such a single fluid jet, multiple fluid jets, a true twisting device, an alternate ply twisting device, an adhesive applicator or the like, a wrapping device, etc.
- each break zone at a speed ratio of 2.0 or greater. This is also advantageous for product throughput efficiencies. It is also desired to provide a large number of filament ends in the consolidated yam. This can be done by making the zone length of the second break zone considerably shorter than the first break zone to shorten the filaments in the fiber and create more filament ends per inch of consolidated yam. It is preferred to make the second break zone length, L2, less than or equal to 0.6 times the first zone length, LI. In a more preferred embodiment, it is desired to make the second length L2 less than or equal to 0.4 times the first length LI . There is a practical limit to the minimum length of the second draw zone where it will be breaking nearly all of the fiber filaments coming from the first zone.
- L2 for break zone 2
- L2 > 0.2 LI The corollary to this logic is that it is desireable to make the first zone considerably longer than the second break zone because it is known that the tension to break filaments decreases in long zones. It is believed important for LI to be long for any given average filament length produced (e.g. established by the second break zone) to decrease the breaking forces required and to present a longer filament length to breaking forces which exposes more filament weak points for breaking.
- Figure 2 shows a fiber 30 comprising only continuous filaments, traveling in a direction 81 and passing through a break zone 34a, such as the first break zone 34 in Fig. 1.
- the break zone 34a extends over a length LI a between two sets of rolls 42a and 50a.
- the speed of fiber 30 is increased in the break zone 34a so that all the continuous filaments being fed in at an upstream end 85 are to be broken in length LI a.
- upstream end 85 refers to a position either just before, just after, or in the nip of roll set 42a.
- upstream refers to the direction the fibers are coming from and downstream refers to the direction the fibers are going toward.
- the fiber has an elongation to break that is expressed in a percent and represents the percent elongation of a filament of the fiber in the direction of an applied load just before the filament breaks.
- Typical elongation to break values for spun manmade fibers before strengthening by drawing can be about 300% for polyester, and after strengthening by drawing can be about 10% for polyester.
- Filament 84 is referred to as a floating uncontrolled filament since it has neither upstream end 84a or downstream end 84b gripped and controlled by either roll set 42a or 50a.
- Filament 86 is referred to as a single gripped uncontrolled filament with a downstream uncontrolled end since it is gripped and controlled only by one roll set 42a and a downstream end 86a is uncontrolled by either roll set 42a or 50a.
- Filament 88 is referred to as a single gripped controlled filament which is gripped and controlled by one roll set 50a and has upstream end 88a which is not gripped by either roll set 42a or 50a. End 88a is less of a problem than end 86a in that it is being pulled through the process rather than being pushed as is end 86a. End 88a is less likely to separate from the central region of the fiber as does end 86a.
- Filaments 90 and 92 are referred to as double gripped support filaments since they are gripped and controlled by both roll sets 42a and 50a at the instant of time shown. They act as a "scaffold" to hold the other uncontrolled filaments in place in the central region of the fiber. They are under significant tension, unlike the other filaments that are only singly gripped, and so they tend to hold the other filaments tightly in the central region and limit the protmsions of ends like end 86a. At a next instant in time, filaments 90 and 92 will be broken, but at that next instance in time other filaments, such as filament 86 whose end 86a will become gripped by roll set 50a, will become double gripped.
- the total number of filaments at the upstream end 85 is equal to the number of double gripped filaments plus the number of uncontrolled filaments, both floating and single gripped.
- a modeling process is used to predict the number of double gripped filaments under a variety of process conditions. The analytical expression works for a single zone with continuous feed filaments. The simulation imposes the same first principles for a multi-zone process where the feed into each zone can be continuous or discontinuous. Single zone results agree well with each other.
- SI - Ln(((D/(l+eb))-l)/(D-l))/(D*(l-(0.5/(l+eb))))
- SI Number of support fibers / Number of uncontrolled fibers
- Ln natural logarithm
- a Monte Carlo computer simulation was developed to analyze a coupled process with multi-zone breaking and drafting.
- the simulation tracks fiber motion through the process, with fiber speed in each zone imposed (as an example) by gripping roll-sets.
- the imposed kinematics dictates the motion of single gripped and double gripped filaments. Randomness occurs during the breaking of double gripped filaments.
- Ismail Dogu "The Mechanics of Stretch Breaking", (Textile Research Journal, Vol. 42, No. 7, July 1972)
- the filament builds up strain until the break elongation is reached, at which time it breaks randomly along the zone length. Filament breaks are independent from others in the fiber.
- Floating filaments are treated in a number of ways, from "ideal drafting” — filaments take on the upstream roll-set speed until the leading end reaches the downstream roll-set — to options where its speed depends on the speed of neighboring filaments. Simulation results agree well with single zone analytical predictions for the support index and process tension, and with measured process tension.
- the simulation model is ran in Matlab® 5.2 from Mathworks, Inc. of Natick, MA 01760. Results can be obtained with a reasonable effort for 1000 filaments on a computer with an Intel Pentium II, 450 MHz processor. It is also practical to handle up to 3000 filaments with this system. Simulation of fiber length distribution for a two-zone breaking process agrees well with the measured distribution.
- the number of double gripped filaments when looking at the number of double gripped filaments it is useful to discuss the number as a percent comparing the number of double gripped filaments to the number of uncontrolled filaments at the upstream end of a zone length, such as upstream end 85 of length LI a.
- the number of double gripped filaments is, by definition, the same at the upstream end 85 and downstream end 93 of zone length LI a.
- the number of uncontrolled filaments is always more at the upstream end than the downstream end of zone length LI a.
- the fiber of discontinuous filaments has been drafted due to the speed ratio, Dla, so the denier of the fiber is always less at the downstream end.
- the curves in the figure relate the total speed ratio to the ratio of double gripped filaments and uncontrolled filaments, N dg /N uc .
- the single zone case is shown in a dashed line 94 with diamond data points and the two zone case is shown in a solid line 96 with square data points.
- the two zone case always provides a higher ratio of double gripped filaments to uncontrolled filaments, which it is believed, will provide better process operability. Looking at the single break zone in Fig. 3, one can see that as the speed ratio increases, the number of double gripped filaments decreases and as the speed ratio decreases, the number of double gripped filaments increases.
- the curve 100 for the second zone has the shape of the curves in Fig. 3. Since the first zone speed ratio is in the denominator, the curve 98 for the first zone has a shape that is the inverse of the curves in Fig. 3. Moving along the horizontal axis, one can see that the lowest value encountered in one of the two zones for N dg /N uc (that will determine an operability limit) is represented by the heavy solid line 102 that includes a portion 104 of the first break zone curve 98 for the values of N dg /N uc less than about 0.7 and includes a portion 106 of the second break zone curve 100 for the values of N dg /N uc greater than about 0.7.
- N dg /N uc drops rapidly below the optimum value of 0.7 for (D2-1)/(D1-1), and drops much less rapidly above 0.7. Also the value for N dg /N uc essentially levels out 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 assure good operability of the stretch-break process using two break zones.
- the modeling simulation process was applied to additional two zone cases and was used to explore the sensitivity of the optimum values for (D2-1)/(D1-1) to maximize the number of double gripped fibers to give an acceptable value of N dg /N uc for good operability.
- Figure 5 shows the sensitivity to the fiber elongation to break parameter.
- Three different curves are plotted similar to the curves in Fig. 4 where each curve represents a different value for the fiber elongation to break, e b .
- FIG. 8 is a schematic elevation view of another embodiment of the stretch- break process line that includes the addition of a draw zone 124 to the embodiment of Fig.
- Fiber 30 which has a first break zone 34, a second break zone 36, and a consolidation zone 38.
- the draw zone may also function as an annealing zone.
- Fiber 30, which may comprise several fibers 30a, 30b, and 30c as in Fig. 1, is now fed into the process at a process upstream end 126 through a zero h set of rolls 128, comprising rolls 130, 132, and 134.
- Roll 132 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and rolls 130 and 134 are driven by their contact with roll 132.
- the fiber 30 is then fed to the first set of rolls 42, thereby defining the draw zone 124 between roll sets 128 and 42.
- the draw zone 124 has a length L4 between the nip of roll 132 and roll 134, which lies on line 136 between their centers, and the nip of roll 44 and 46, which lies on line 138 between their centers.
- the fiber speed is increased within the draw zone 124 by driving the fiber at a feed speed, Sf, with roll set 128 and driving it at the first speed, SI, higher than speed Sf, with roll set 42.
- a fiber heater 140 that may take many forms; the form shown here is a curved surface 142 that contacts the fiber over a length that can easily be varied by changing the length of the arc the fiber follows over the surface 142. For longer heating times at a given fiber speed at the upstream end 126 and a given draw speed ratio D4, the arc and contact length would be longer. Drawing of the fiber may occur as soon as the fiber is exposed to the tension in the draw zone 124, so for some polymers, the drawing or elongation of the fiber may occur just as the fiber is leaving the nip of the upstream rolls, such as rolls 132 and 134. For some polymers, the draw occurs over a very short length, such as less than 1.0 inch.
- the heater serves to anneal the drawn fiber rather than heat it for drawing.
- the rolls 132 and 134 may be heated.
- Other polymers may not draw until they experience some heat by contact with the surface of the heater 140.
- the length of the draw zone is not critical, and is primarily sized to accommodate the heating device 140.
- the fiber would be drawn without heating (the heater would be turned off and retracted from contact with the fiber) and in other cases, the fiber would be heated during the drawing process as shown.
- the fiber may have a draw speed ratio D4 equal to about one and the fiber may only be heated without stretching. In this case, the draw zone would function as an annealing zone.
- a draw zone and drawing the fiber refers to stretching continuous filament fiber in a way that essentially none of the filaments are broken; the filaments remain continuous. Heating the fiber may or may not be included in drawing.
- An annealing zone and annealing the fibers refers to heating a continuous or discontinuous filament fiber while constraining the length of fiber without significant stretching, and may include some small overfeed of the fiber into the annealing zone where D4 is a number slightly less than 1.0.
- a new product can be made comprising feeding at least two different fibers into the process and combining them before breaking in the break zone, the fiber differences being differences in denier per filament and one of the fibers having a denier per filament of less than 0.9 and the other fiber having a denier per filament greater than 1.5.
- the two fibers would go through the break and consolidation zones together.
- the two different fibers can be combined as a feed yam either by spinning a single fiber bundle with two different dpf or by bringing together two different fibers each with a different dpf. In the draw zone, the elongation to break of the fibers should be similar.
- FIG. 9 is a schematic elevation view of another embodiment of the stretch- break process line that includes the addition of a draft zone 144 to the embodiment of Fig. 8 which has a draw zone 124, a first break zone 34, a second break zone 36, and a consolidation zone 38.
- the draft zone 144 is added between the second break zone 36 and the consolidation zone 38.
- the fiber 30, exiting the second break zone 36 as in Fig. 8, is now fed into the draft zone after roll set 62.
- the fiber 30 is then fed to a fifth set of rolls 148, comprising rolls 150, and 152, thereby defining the draft zone 144 between roll sets 62 and 148.
- Roll 152 is driven at a predetermined speed by a conventional motor/gearbox and controller (not shown) and roll 150 is driven by its contact with roll 152.
- the draft zone 144 has a length L5 between the nip of roll 62 and roll 68, which lies on line 80 between their centers, and the nip of roll 150 and 152.
- the fiber speed is increased within the draft zone 144 by driving the fiber at a speed S3 with roll set 62 and driving it at the fifth speed S5, higher than speed S3, with roll set 148.
- the length L5 should be about the same length as the adjacent upstream break zone, in this case, the second break zone length L2 in the configuration shown.
- a draft zone and drafting the fiber refers to increasing the fiber speed in a zone for the primary purpose of reducing the denier of discontinuous filament fiber in a way that more than 80% of the fibers remain their same length, that is, 20% or less of the fibers are broken. It is intended that the draft zone can be at various locations as long as it is upstream from the consolidation zone, for instance, it may be between the first break zone and second break zone.
- a process approximating that illustrated in Fig. 8 was operated and data was collected to determine the limits of good operability, which are plotted in Figure 10.
- Fig. 10 shows the curves of Fig. 4, with the left vertical axis expanded and a right vertical axis added to permit plotting of some actual process cases that were run to find the limits of good operability.
- FIG. 10A shows the data that was collected.
- the circled data points in Fig. 10A are those that were plotted in Fig. 10.
- a curve for the optimum operating point for (D2-1)/(D1-1) 0.7 for a variety of total draw ratios in also shown at 155; the maximum total speed ratio for good operability along this line was found to be 42.8X at point 157. For different materials and different zone lengths, these data would be different.
- the finish used on the fiber is also a consideration for operability. Too much finish and the independent filament mobility and breaking in the stretch break zones is adversely affected and complete fiber break down occurs; too little finish and static becomes a problem and roll wraps are increased. A finish level of less than about 0.1% is preferred and less than about 0.04% is more preferred.
- a typical finish having 0.04% of a finish comprises a mixture of an ethylene oxide condensate of a fatty acid, an ethoxylated, propoxylated alcohol capped with pelargonic acid, the potassium salt of a phosphate acid ester, and the amine salt of a phosphate acid ester.
- Other finishes that may be useful for stretch breaking fiber are found in the 778 reference to Adams and Japanese Patent Publication 58[1983]-44787 to Hirose et al. Referring again to Fig. 10, connecting the data points with line 158 allows one to compare the test data to the simulation curves 98 and 100 taken from Fig. 4.
- the feed fiber 30 is supplied from one or several of a container 160 of piddled fiber or alternatively, feed fiber can be fed from one or several of a wound package 162.
- the fiber 30 passes through some breaker guides 164 that can be used to bring together multiple ends of fiber and allow the fiber to distribute in a flat ribbon.
- the fiber then goes over a guide roll 166 and to a roll set 128a comprising four rolls 168, 170, 172, and 174, and a nip roll 175, for gripping the yam securely at the upstream end of a draw zone 124 during threadup of the fiber.
- All rolls 168-174 are driven by a conventional electric motor/gearbox and controller (not shown), and nip roll 175 is driven by contact with roll 168.
- the downstream end of the draw zone 124 is defined by another roll set 42a comprising four rolls 176, 178, 180, and 182, and a start up nip roll 184. All rolls 176- 182 are driven by a conventional electric motor/gearbox and controller (not shown).
- Start up nip roll 184 is driven by contact with roll 182. It is used to get the fiber started through the process and it is then retracted out of contact with roll 182.
- an electric heater 140 with curved surface 142 that can have a variable contact length with the yam as discussed referring to Fig. 8.
- a source of electrical power (not shown) is attached to the heater.
- a first break zone 34 with roll set 50a at the downstream end which is identical to the roll set 50 in Figs. 1 and 8.
- Within first break zone 34 is an electrostatic neutralizer bar 186 adjacent drawn and stretch- breaking fiber 30; and a swirl jet 188 through which the fiber 30 passes.
- the electrostatic neutralizer bar is electrically energized by an electrical power source (not shown) and is the type sold by Simco, model no. ME 100.
- Point source static eliminator devices such as devices 187 may be used in place of or in addition to the bar 186 to control static, especially in the vicinity of the roll sets.
- Another method of combating these problems is gathering the loose filament ends in the break zone and adjacent the exit nip rolls and directing them toward the fiber core so the loose ends in the lateral directions around the core are constrained to be within a distance from the center of the core of not greater than the distance of the center of the core from each respective end of the exit nip rolls for the break zone to minimize wrapping of the loose ends on the exit nip rolls. It is important to apply this method of control in the first break zone where the loose filament lengths may be longer and unsupported over a longer length. It is also advantageous to apply it to the second break zone where loose fibers are still present. A swirl jet 188 is one way to accomplish this method.
- the swirl jet 188 introduces a jet of gaseous fluid to gently swirl loose filaments around the central region of the fiber, or fiber core, which is a flat ribbon-like structure.
- the swirl jet is shown in greater detail in Figure 12.
- the swirl jet 188 comprises a body 192 having an upstream end 194, a downstream end 196, and a cylindrical bore 198 extending throughout the length of the body 192.
- the fiber 30 passes through the bore 198 on its way to roll set 50a (see Figure 11).
- a fluid passage 200 extends through the body and is in fluid communication with the bore 198 at the upstream end 194 of the body.
- the fluid passage intersects the bore in a way that the fluid is introduced approximately tangent to the bore and angled toward the downstream end 196 of the body.
- a counterclockwise swirling fluid flow (referenced at end 196), generally indicated by the spiral flow path 202, is generated within the bore 198.
- This fluid flow tends to wrap loose filaments, that extend from the central region of the fiber 30, around the fiber core to eliminate long loose ends that may wrap on downstream rolls.
- the wrapped filaments are loosely gathered around the fiber core.
- a thread up slot 204 is provided in the body 192 along the length of the bore 198 to facilitate threading the fiber 30 in the swirl jet bore.
- Another way to accomplish the method of gathering the loose filament ends in the break zone and adjacent the exit nip rolls and directing them toward the fiber core is to use a trough as shown in Figures 34A and 34B.
- a trough 450 has a shaped end 452 which is spaced adjacent a nip roll set, such as roll set 50a (Fig. 11) at the end of the first break zone 34.
- the trough has a longitudinal cavity 454 that is sized to accommodate the fiber 30 in the zone and has a width 456 that gathers the loose filaments 458 and 460 on the sides of the fiber core 462 and constrains them from extending out to the ends of the nip rolls in the roll set.
- the surface of the cavity facing the fiber is an electrically conductive surface.
- Nip roll 54a has ends 462 and 464 and nip roll 52a has ends 466 and 468.
- the center of the fiber core is indicated at 470 and the trough directs the loose filaments toward the fiber core 462 so the loose ends, such as ends 458 extending laterally around the core are constrained to be within a distance from the center of the core of not greater than the distance 472 of the center of the core from end 468 of the exit nip roll 52a and distance 474 from the end 464 of exit nip roll 54a; in this case, the lesser distance 472 is controlling.
- the loose ends such as ends 460 extending laterally around the core are constrained to be within a distance from the center of the core of not greater than the distance 476 of the center of the core from end 466 of the exit nip roll 52a and distance 478 from the end 462 of exit nip roll 54a; in this case, the lesser distance 476 is controlling.
- the trough 450 may only be adjacent the nip rolls exiting the zone and extend a short distance therefrom, or it may extend for nearly the entire length of zone 34 to maintain control of the loose filaments throughout the zone.
- the trough 450 may optionally have a cover 480 to fully contain the loose filaments in all directions, however, it is most important that the trough contain the filaments laterally to keep them from extending to the ends of the nip rolls where they are susceptible to wrapping on the nip rolls. If a cover is used, it should have access for an air ionizing device.
- a second break zone 36 with roll set 62a at the downstream end, which is identical to the roll set 62 in Figs. 1 and 8.
- Within second break zone 36 is an electrostatic neutralizer bar 206 adjacent the drawn and stretch-breaking fiber 30; and a swirl jet 208 through which the fiber 30 passes. This is similar to the configuration of the first break zone just discussed.
- Aspirator jet 212 provides a gentle flow of gaseous fluid in the direction of travel of fiber 30 to capture and propel loose filaments ends coming out of the roll set 50a so they will not wrap on the rolls in roll set 50a.
- Aspirator jet 212 is the type available from Airvac model no ITD 110.
- Such an aspirator may also be used in the first break zone 34 next to roll set 42a if the fiber entering the zone has some discontinuous filaments present.
- a draft zone 144 with roll set 148a at the downstream end which is identical to the roll set 148 in Fig. 9.
- an aspirator jet 214 Within draft zone 144 is an aspirator jet 214, snubbing bars 216, and guide bars 218.
- the snubbing bars provide some resistance to filament drafting to give a more uniform denier to the fiber. It may also be useful to provide a swirl jet, such as swirl jet 208, upstream and adjacent the roll set 148a.
- a consolidation zone 38 Following roll set 148a is a consolidation zone 38 with roll set 74a at the downstream end which is identical to the roll set 74 in Figs. 1, 8 and 9.
- an aspirator jet 220 and an interlace jet 83a Within consolidation zone 38 is an aspirator jet 220 and an interlace jet 83a. In practice, interlace jet 83a is usually placed in the consolidation zone 38 at a distance from roll set 148a of about 1/3 to 1/2 of the length of the consolidation zone.
- Figure 26 shows the interlace jet 83a in a perspective view and Figure 27 a cross section view with a stretch broken fiber 30 entering the fiber passage 320.
- the fiber passage 320 preferably has a rounded triangle cross-section, seen at the entrance end 322.
- the jet 83a has a first groove wall 324 in an entrance guide surface 326 that provides a coanda effect in conjunction with entrance exterior surface 328 at the entrance end
- a fluid inlet passage 338 provides fluid to the fiber passage 320 to interlace the fiber to consolidate it into a yam.
- the fluid passage 338 is arranged at angle 340 toward the downstream end of the jet at exit end 334, in the direction of the fiber travel through the jet, to minimize the exhaust of fluid out of the upstream end of the fiber passage.
- interlace jet yam passage 320 is arranged at an angle 342 relative to the fiber path 344 between roll set 148a and 74a (Fig. 11) so that fluid which does exhaust out the upstream end of the yam passage is directed downward away from the fiber path.
- Guides 346 and 348 may be employed to assist in guiding the fiber through the jet. This handling of exhaust fluid from the upstream end of the yam passage minimizes the spreading of any loose filaments in the fiber as the fiber enters the interlace jet.
- Such an interlace jet 83a is described in more detail in U.S. Patent 6,052,878 to Alfred et al, which is hereby incorporated herein by reference. Other filament interconnecting jets would work in this embodiment.
- the pneumatic torsion element 83b comprises an injector component or first nozzle 350, having a spinning bore 351, and a torsion component or second nozzle 352, having a spinning bore 353.
- the two components are held in relation to one another by a common holding device 354 that also houses a first evacuation chamber 356 and a second evacuation chamber 358 for cleaning up debris associated with the fiber.
- the stretch broken fiber 30 first passes through the bore of first nozzle 350. It is believed that this first nozzle acts to forward the fiber and apply some twist to loose filaments at the periphery of the twisting fiber core that is formed by the second nozzle. The fiber then passes through the bore of second nozzle 352.
- this second nozzle acts to twist the filaments in the fiber core upstream of the second nozzle and through the first nozzle without creating interlace between the filaments in the yam.
- First evacuation chamber 356 is located adjacent the exit end 360 of first nozzle 350 and is in fluid communication with a source of vacuum at one side 362 and is in fluid communication with the atmosphere at an opposite side 364. Air flowing from side 364 to 362 across the path of the fiber removes loose broken filaments and polymer or finish powder and dust from the fiber path. The fiber then passes through the second nozzle 352 and through a string-up opening 366 and the second evacuation chamber 358. Both the string-up opening and second evacuation chamber are near the exit end 368 of the second nozzle 352.
- the second evacuation chamber 358 includes a string- up slot 370 along its length that may be covered after string-up by a cylindrical cover (not shown).
- Such a cover may rotate about the outer surface 372 of the holding device 354 to cover and uncover the slot, when the surface is a cylindrical surface surrounding the chamber 358 that mates with the cover.
- the second evacuation chamber is in fluid communication with a source of vacuum at one side 374 and is in fluid communication with the atmosphere at string-up slot 370 (when the cover is open or absent) and ends 376 and 378. Air flowing from ends 376 and 378, and through slot 370, pass along the path of the fiber and remove loose broken filaments and polymer or finish powder and dust from the fiber path. Operation of the torsion element 83a is not dependent on the first and second evacuation chambers, but they contribute to reliability of the element by keeping it clean.
- the first nozzle or injector component 350 has pressurized gas, preferably air, supplied through a line 380 into a ring channel 382 that directs the fluid to multiple compressed fluid channels, such as 384 and 386.
- Channels 384 and 386 intersect the spinning bore 351, having a diameter d], in a known fashion at a location tangent to the bore diameter and at an angle 388 slanted toward the direction of fiber travel through the bore.
- the intake opening 389 of bore 351 of first nozzle 350 may be a straight cylindrical shape as shown or may be conically tapered and include notches to influence the propagation of twist in the fiber.
- the second nozzle or torsion component 352 likewise has air supplied through a line 390 into a ring channel 392 that directs the fluid to multiple compressed fluid channels, such as 394 and 396 which intersect bore 353, having a diameter do-
- First nozzle 350 has a characteristic distance from end 360 to a channel such as 386, and second nozzle 352 has a characteristic distance I D from an entrance end 398 to a channel such as 396.
- the first nozzle 350 is spaced from the second nozzle 352 by a distance "a" measured between compressed fluid channels where they intersect the spinning bore of each nozzle.
- This distance is adjusted for the particular fiber being processed and may be larger for fibers that have a large average filament length and smaller for fibers having a small average filament length.
- the first and second nozzles 350 and 352 are adjustably held in place in common holding device 354 by fasteners, such as setscrews (not shown) to facilitate adjustment of the distance "a".
- each nozzle may have independent holding devices and be mounted spaced apart on the machine frame (not shown).
- the pneumatic torsion element 83b is placed in the consolidation zone 38 in place of the device 83a and aspirator 220 is removed.
- the first nozzle 350 is set as close as possible to the nip roll set 148a (Fig. 11), being about 1.0 inch from the nip to the first nozzle location where the fluid channels 384 and 386 intersect spinning bore 351.
- the second nozzle is set at various distances "a" away from the first nozzle location measured to where the fluid channels 394 and 396 intersect spinning bore 353.
- Figure 35 shows a plot of yam strength for a yam having an average filament length "avg", with data points for each average length measured at different spacings "a" between the fluid channels in the first and second nozzles, 350 and 352, respectively in Fig. 28.
- "a" several yam samples are taken and an average strength number in grams per denier (gpd) is obtained by the Lea Product method.
- gpd grams per denier
- the consolidated yam is directed to a winder 222.
- the winder comprises a dancer arm and grooved roll 228 attached to a controller (not shown) for controlling the winder speed; a traverse mechanism 230 for traversing the yam 32 along the axis of a yam package 232; and a driven spindle 234.
- the winder is of a conventional design that requires no further explanation to one skilled in winding art.
- Figure 11 shows a process with all the functional zones that in some way treat the yam being in essentially a straight line path.
- Figure 11 shows the functional zones of the draw zone 124, the first break zone 34, the second break zone 36, the draft zone 144, and the consolidation zone 38 all in a line from left to right, the fiber following a substantially straight path through each functional zone, each functional zone path defining a unit path vector (a vector having a direction, and a magnitude of unity) having a head in the direction of fiber travel and a tail.
- the process functions well, but it takes up a lot of floor space. For production machines in a factory, optimum use of floor space is important to keep costs down.
- Figure 32 shows a stretch breaking apparatus 400 for a process where the path of the fiber through one or more of the functional zones is arranged to be folded so when a path vector in a first functional zone is placed tail to tail with a path vector in a next sequential functional zone there is defined an included angle that is between 45 degrees and 180 degrees resulting in a compact floor space for the process.
- the stretch break apparatus 400 comprises a draw zone 402 between roll sets 404 and 406, a first break zone 408 between roll sets 406 and 410, a second break zone 412 between roll sets 410 and 414, and a consolidation zone 416 between roll sets 414 and 418.
- the consolidated yam is wound up on a winder system at 420.
- the apparatus 400 also includes a heater 140, an electrostatic bar 186, swirl jets 188 and 208, a consolidation device 83, such as 83a (Figs. 26 and 27) or 83b (Fig. 28), and various other forwarding jets, guides, nip rolls, etc.
- a heat shield 417 between heater 140 and the first break zone 408.
- a second fiber feed is present at 419 after the draw zone 402 and before the first break zone 408.
- a third fiber feed location is present at 421 after the second break zone 412 and before the consolidation zone 416.
- a feed fiber 30 enters the stretch break apparatus 400 from a creel, not shown, at position 424 in direction of a path vector 426 having a head 425 and a tail 427.
- Path vector 426 is not a path vector for a functional zone, since the fiber is just being transported at this point and is not being treated in any way.
- the fiber 30 passes through roll set 404 and travels along a path vector 428 through the functional zone for drawing the fiber, draw zone 402.
- the fiber 30 then passes through roll set 406 and travels along a path vector 430 through the functional zone for breaking, first break zone 408.
- the fiber then passes through roll set 410 and travels along a path vector 432 through the functional zone for breaking, second break zone 412.
- FIG. 33A sequential functional zone path vectors 428 and 430 are placed together tail to tail.
- Path vector 430 is placed with its tail coinciding with the tail of path vector 428 and the included angle between the two straight line vectors is indicated at 436 and is about 180 degrees.
- Fig. 33B sequential functional zone path vectors 430 and 432 are placed together tail to tail.
- Path vector 432 is placed with its tail coinciding with the tail of path vector 430 and the included angle between the two straight line vectors is indicated at 438 and is about 90 degrees.
- sequential functional zone path vectors 432 and 434 are placed together tail to tail.
- Path vector 434 is placed with its tail coinciding with the tail of path vector 432 and the included angle between the two straight line vectors is indicated at 440 and is slightly more than 90 degrees.
- the path vector 430 of the fiber in the first break zone 408 extends in one direction and the path vector 434 of the fiber in the consolidation zone 416 is folded to extend in a direction substantially 180 degrees opposite to the path in the break zone. This makes for a compact a ⁇ angement taking up a minimum of floor space. It is not necessary that all sequential functional zones be folded, but to save space, at least two sequential zones should have the fiber path folded going from one zone to the next.
- This folding of the paths of the fiber through the functional zones so that when a path vector in a first functional zone is placed tail to tail with a path vector in a next sequential functional zone there is defined an included angle that is between 45 degrees and 180 degrees, results in a compact floor space for the apparatus to practice the stretch breaking process.
- there may be a plurality of included angles each between sequential functional zones where the fiber path is folded.
- the folded path system of the invention is alternatively defined when the sum of the absolute value of all the individual included angles between sequential functional zones is preferably 90 degrees or more and is most preferably 180 degrees or more.
- the arrangement shown in Fig 32 is only one folding a ⁇ angement for a stretch breaking process and the concept of folded paths is applicable to other stretch breaking processes and other a ⁇ angement of path vectors.
- the yam produced by the apparatus of Fig. 11 is a discontinuous filament staple yam with a denier that can be readily used in textile end applications without further preparation other than conventional dyeing or the like.
- the linear density of the staple yam product is typically about equal to or less than 1000 denier, or alternatively, is a staple yam having 500 or less filaments per cross-section where the linear density may be more than 1000 denier.
- Such a process comprises: withdrawing a fiber at a speed greater than 1.0 meter per minute from a container holding continuous filament fiber that has been piddled therein, the fiber having a denier of between 2,000 - 40,000 and the container holding between 10-200 pounds of fiber, and feeding the fiber to a fiber break zone, and breaking the fiber in the break zone by increasing the fiber speed within a predetermined zone length at a speed ratio greater than 2.0, and consolidating the fiber downstream from the break zone to form a staple yam.
- the piddled fiber is preferably obtained most economically by a modified method of operating a staple fiber spinning machine having a single polymer supply system feeding multiple spinning positions normally combined together to make a single large denier tow product collected into a container to be later converted to staple fiber.
- Figure 29 illustrates such a system having a staple fiber spinning machine 500 with, for instance, 10 positions, such as individual positions 502, 504, 506, 508 and 510, the machine provided with polymer from a single supply at 511. The positions are all combined into a large denier tow product 512, which is piddled into a large container 514.
- the container 514 holding over 1000 lbs of product is combined with other containers and goes through a conversion process, generally designated at 516 that ultimately results in staple fiber being spun into yam in a carding, combing, spinning system 518.
- a conversion process generally designated at 516 that ultimately results in staple fiber being spun into yam in a carding, combing, spinning system 518.
- he improvement comprises managing the operation of the modified staple spinning machine 501, having at least about 10 spinning positions, to simultaneously produce a plurality of low denier tow products rather than a single large denier tow product, the low denier products each being less than about 20% of the large denier tow product.
- An individual low denier tow product 30 comprises at least 500 fibers at a spinning position that is collected into an individual container 160 holding about 20 (-9.07 kg) to 200 (-90.72 kg) lbs of low denier tow product.
- the means for collecting the individual low denier tow product comprises a piddle device 524 or a winder (not shown); preferably a piddle device is used to collect undrawn product into the container 160 in a way that the product can be stored, transported and withdrawn for further processing.
- a wound package on a tube core from a winder is also a container from which the product can be stored, transported and withdrawn for further processing.
- the new method of operating the staple spinning machine also includes changing the fiber product characteristics for at least one spinning position making the low denier product such that the fiber product characteristics differ from the remaining spinning positions making either the low denier product or the large denier product.
- Such changed fiber product characteristics may include a different denier per filament, a different finish, a different color by direct color injection at the spinning position, a different filament cross section, or other fiber differences commonly available at an individual spinning position.
- the new method of operating the staple spinning machine further comprises providing a means to process the low denier tow product from at least one spinning position to convert the low denier tow product to a spun yam product.
- Such means illustrated in Figs. 30 and 31 would preferably comprise the stretch break machine 522 of the invention being supplied from the piddled fiber container 160.
- the machine could comprise the '463 reference to Minorikawa or the '778 reference to Adams or the like which converts continuous filament fiber to discontinuous filament staple yam.
- Each position on the staple fiber spinning machine could supply the needs of maybe 10 spinning positions, such as position 526, on a stretch break machine 522 so that many stretch break machines, such as 522 and 522a, each with a plurality of positions could be supplied with fiber from a single staple spinning machine 500.
- the feed yam 30 can be provided in the piddle container 160 of Figs. 11, 30, and 31 by a piddling device as disclosed in US patent 4,221,345 or it can be provided by a device as illustrated in Figures 13 and 14.
- Figure 13 shows a piddler device 236 that comprises a guide roll 238, an idler roll 240, a drive roll 242, an aspirating jet 244, a fiber distributing rotor 246, a rotor driver 248, a container 250, and a container oscillator 252.
- the fiber 30 can come from a staple spinning machine for continuous man-made filaments, such as the staple spinning machine 501 or 503 in Figs. 30 and 31, respectively.
- the guide roll 238 guides the fiber to an idler/drive roll combination, rolls 240 and 242 respectively, where the fiber makes at least one complete wrap as shown by the a ⁇ ows 254 and 256 before being fed to the aspirator jet 244 in the direction of a ⁇ ow 258.
- the fiber is propelled by a gaseous fluid in the aspirator jet toward an entrance passage 260 in the rotor 246 which is being rotated continuously by rotor driver 248.
- the fiber passes through the rotor 246 and leaves through a passage exit 262.
- the fiber then descends in a spiral path 264 into the container 250.
- the container oscillator moves the container slowly under the rotor to progressively fill the container with back and forth layers of spiral-laid fiber.
- Such a piddle device can operate at speeds consistent with conventional spinning positions and deposit fiber in a way that it can be removed from the container at a slow speed consistent with stretch-breaking speeds.
- Figure 14 shows a detailed cross-section view of the rotor 246, which has a body 266.
- the entrance passage 260 is located on top of the body 266 at the center of rotation of body 266, and is connected to the passage exit 262 by an angled passage 268 which the fiber 30 (Fig. 11) and fluid from aspirating jet 244 (Fig. 13) can easily pass through.
- a balancing hole 270 is provided opposite passage exit 262 to balance the rotor and minimize vibration during rotation.
- the unique stretch-broken yam has a particular average filament length, a maximum filament length and a range of filament lengths. Such a stretch-broken yam has a useful number of filament ends per inch. A substantial percentage of these numerous filament ends can be found as protruding ends extending from the central portion of the yam to give the yam a desirable feel or "hand".
- the yam has a numerical average filament length (versus a weight average) that is greater than 6 inches, the maximum length of 99% of the filaments is less than 25 inches, and the middle 98% of the filament lengths defines a length range that is greater than or equal to the average length.
- the range equals the maximum length of the mid 98% samples minus the minimum length of the mid 98% samples.
- the yam can also be characterized as a consolidated, manmade fiber of discontinuous filaments of different lengths, the filaments intermingled along the length of the yam to maintain the unity of the yam, wherein the average length, avg, of the filaments is greater than 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 that is greater than 1.5 times the average length, avg.
- the filament length distribution also has 5% to less than 15% of the filaments having a length less than 0.5 times avg.
- the histogram in Fig. 15 represents the actual yam sample filament length distribution and is labeled 271.
- the filament lengths were pulled from the fiber before consolidation so they could be easily removed. No draft was employed.
- the filament lengths were obtained by the process described in US 4,118,921 under the sections entitled “Average Fiber Length”, “Fiber Length Distribution”, and “Fiber Length Histogram", hereby incorporated herein by reference. It was known by denier measurement and calculation that there were about 192 filaments in the fiber cross- section coming from the second break zone, so 500 filaments were removed from the new end of fiber and the lengths were recorded and grouped in one inch increments.
- the procedure to get this number of filaments was to repeat the process under "Average Fiber Length" after each batch of 100 filaments. This resulted in the histogram 271 of fiber length and frequency of Fig. 15.
- the model simulation of the process was set up the same as the actual test process to predict the filament length distribution represented by curve 272 of Fig. 15. As can be seen, the simulation of the filament length distribution is close to the actual filament length distribution.
- the numerical average filament length was 11.0" (-27.94 cm), and for the simulation the average filament length was 11.1" (-28.2 cm).
- the length of the middle 98% of filament lengths was from 3" (-7.62 cm) to 18" (-45.72 cm) for a range of 15".
- the lengths were from 3.5" ( ⁇ 8.89 cm) to 19.5" ( ⁇ 49.53) for a range of 16" (-40.64 cm).
- the maximum length of 99% of the filaments was 18" (-45.72 cm), and for the simulation, the maximum length was 19.5" ( ⁇ 49.53 cm).
- Simulation values in these cases were within 10% of the actual values.
- the number of filaments having a length less than 0.5 times the average, avg, and the number greater than 1.5 times the average were measured and simulated.
- the measured results are 8.2 % less than 0.5 avg and 5.0% greater than 1.5 avg.
- the simulated results are 11.16% less than 0.5 avg and 10.27% greater than 1.5 avg.
- the break zone length LI is 30" (-76.2 cm) and the percentage of double gripped filaments is low.
- the filament distribution of CE1 is plotted in Figure 16
- the break zone length is 10" and the average filament length is less than 6.0" which is believed to contribute to lower strength yam when interlacing is used for consolidation.
- the filament distribution of CE2 is plotted in Figure 17 where it is seen the maximum length of 99% of the filaments is less than 25" (-63.5 cm) which is an improvement over ex. CE1.
- Example Al shows that a reduction in the second break zone speed ratio and increase in the first break zone ratio results in a favorable value for (D2-1)/(D1-1) of 2.0. It is expected this would result in an operability improvement over example A.
- Example B shows a condition where the first and second break zones are operated at the same speed ratio of 5.
- Example Bl illustrates that by reducing the second break zone speed ratio and increasing the first break zone speed ratio one would expect to improve the operability of the second zone so both zones have the same high percentage of double gripped filaments.
- the approximated value of 3.8% is obtained from the plot of Fig. 4 at a value of (D2-1)/(D1-1) of 0.7.
- Example G has a co ⁇ espondingly lower filament ends per inch than ex. C, although the reduced denier of feed yam and increased speed ratio also contribute to the lower value.
- L2 0.2 LI, but this change is not enough to make much difference compared to examples B and C respectively.
- the fiber 30 may contain filaments prepared from materials selected from the group consisting of nylon, polyester, an aramid (a polymer derived for example from m- or 7-phenylenediamine and terephthaloyl chloride), a fluoropolymer, an acetate polymer or copolymer, an acrylic polymer or copolymer, polyacetal, an acrylate polymer or copolymer, polyacrylonitrile, a cellulose polymer, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), polyimide, a styrenic polymer or copolymer (including for example, styrene/acrylonitrile), an ether/ester copolymer, a copolymer of an amide with an ether and/or ester, a vinyl polymer such as poly(vinyl chloride) or poly(vinyl alcohol), and a polyimide; and mixtures of any two or more thereof
- Prefe ⁇ ed choices for the fiber 30, if it is to be drawn may include, for example, nylon, polyester, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), an ether/ester copolymer, an acrylic polymer or copolymer, polyacetal, poly( vinyl chloride), and mixtures of any two or more thereof.
- an olefin polymer or copolymer such as an ethylene or propylene polymer or copolymer
- an ether/ester copolymer such as an ethylene or propylene polymer or copolymer
- an acrylic polymer or copolymer such as polyacetal, poly( vinyl chloride), and mixtures of any two or more thereof.
- Figure 20 shows the process schematic of Figure 9 where a new stretch-broken product can be made by introducing to fiber 30 an additional feed fiber 31 a at the downstream end 300 of the draft zone 144 which is the also the upstream end of the consolidation zone 38. Since the fiber 31a will not be subjected to any drafting, the filaments in the fiber 31 a can be continuous or discontinuous. If continuous filaments are used, they can be high strength filaments with low elasticity.
- the fiber 31a may contain filaments prepared from materials selected from the group consisting of nylon, polyester, an aramid (a polymer derived for example from m- orp- phenylenediamine and terephthaloyl chloride), a fluoropolymer, an acetate polymer or copolymer, an acrylic polymer or copolymer, polyacetal, an acrylate polymer or copolymer, polyacrylonitrile, a cellulose polymer, an olefin polymer or copolymer (such as an ethylene or propylene polymer or copolymer), polyimide, a styrenic polymer or copolymer (including for example, styrene/acrylonitrile), an ether/ester copolymer, a copolymer of an amide with an ether and/or ester, a vinyl polymer such as poly(vinyl chloride) or poly( vinyl alcohol), and a polyimide a polyurethane, a cop
- the fiber 31a may, for example, be an aramid fiber, or it can be a filament with high elasticity, such as a spandex-type fiber or a 2GT (1 ,2-ethane diol (or ethylene glycol) estrified with terephthalic acid) or a 3GT (1,3-propanediol (or 1,3 propylene glycol)- 3GT (estrified with terephthalic acid) polyester fiber.
- a prefe ⁇ ed spandex-type fiber is one with elastic filaments having an elongation to break greater than about 100% and an elastic recovery of at least 30% from an extension of about 50%.
- Fibers 30 may, for example, be a copolymer having blocks of polyurethane and blocks of polymerized ethers and/or esters.
- additional fibers 31a can be added to fibers 30 that preferably include a polymer such as nylon, polyester, aramid, fluoropolymer or Nomex® (brand name for a fiber and paper with raw materials of isophthalyl chloride, methpenylene diamine).
- Kevlar® aramid fiber of continuous filaments has been combined with polyester in one product; and Lycra® elastic fiber of continuous filaments has been combined with polyester in another product.
- continuous filaments, wires or fibers of such materials as metals, glasses, fiberglasses or polymers can be added to the yam in position 31a of Figure 20.
- Metallic wires or filaments of electrically conductive polymers will provide the capability of ca ⁇ ying electrical cu ⁇ ent to the resulting yam.
- a fabric of such yam could be resistively heated or could carry electronic signals.
- Continuous filaments, wires or fibers can add strength and cut resistance to the resulting yam.
- Optical fibers could carry optical signals.
- the broken fibers of the yam are consolidated around the continuous filament, wire or fiber.
- the consolidated broken fibers may act, for example, as electrical or optical insulation.
- Figure 21 shows the process schematic of Figure 9 where a new stretch-broken product can be made by introducing an additional feed fiber 3 lb at the downstream end 302 of the draw zone 124 which is also the upstream end of the first break zone 34, or at the downstream end 303 of the first break zone 34 which is also the upstream end of the second break zone 36.
- This is useful if fibers 31b, which do not require drawing, are to be added to drawn fibers 30. Both fibers 30 and 31b would be broken at the same time in the first break zone 34 and would continue to be treated together throughout the remainder of the process.
- the fiber 31b may be selected from any of the same group as set forth above for the fiber 30.
- Such additional fibers 31b are preferably of the polymer group including aramid, fluoropolymer, and Nomex® aramid, and they are added to fibers 30 that preferably include a polymer from the group of nylon or polyester.
- Fibers could be added the 3 lb position so that the that fiber is broken along with the yam 30.
- Such fibers appropriate for addition at position 3 lb include Bemberg®, whose generic name is Cupro and is a type of regenerated natural celluose made from cottoen linter, acetate, and acrylic.
- One such blend is a blend of nylon and Coolmax® polyester that could be co-drawn; or one component could be pre- drawn and fed at position 31b.
- Another blend is a blend of nylon and Nomex® aramid with the aramid being added at position 31b.
- acetate would be added at position 31b.
- Nomex® aramid and Tefzel® fluoropolymer neither component would be drawn. This blend could be fed to the draw zone at a draw ratio of 1.0, or the blend could be fed at position 31b.
- Figure 22 shows the process schematic of Figure 9 where a new stretch-broken product can be made by introducing a first additional feed fiber 31b at the downstream end 302 of the draw zone 124 which is also the upstream end of the first break zone 34 (or at the downstream end 303 of the first break zone 34 which is also the upstream end of the second break zone 36); and also introducing a second additional fiber 31a at the downstream end 300 of the draft zone 144 which is the also the upstream end of the consolidation zone 38.
- a particularly prefe ⁇ ed embodiment is to introduce a fluoropolymer as the first additional fiber 31b, a spandex-type fiber as the second additional fiber 31a with both additional fibers joining a fiber 30 of polyester.
- a yam product is useful as a textile yam for weaving or knitting socks.
- Another product combined discontinuous polyester, as a first feed fiber that was drawn, with a first additional feed fiber of Kevlar® aramid that is stretch broken with the polyester, and that combination combined with a second feed fiber of Lycra® elastic fiber of continuous filaments to form a three component yam.
- the fibers 30, 31 a and 31b may contain filaments prepared from one or more material(s) selected from the respective groups set forth above.
- the fibers 30, 31a and 31b may also, however, contain filaments prepared from one or more material(s) selected from a subgroup formed by omitting any one or more members from any of the whole group as set forth in the lists above.
- the fibers may in such instance not only be contain filaments prepared from one or more material(s) selected from any subgroup of any size that may be formed from any of the whole groups as set forth in the lists above, but the fibers may also be made in the absence of the members that have been omitted from a whole group to form a subgroup.
- a subgroup formed by omitting various members from a whole group in a list above may, moreover, be an individual member of the whole group such that the fiber is made in the absence of all members of the whole group except the selected individual member; or a subgroup formed by omitting various members from a whole group in a list above may contain any number of the members of the whole group such that those members of the whole group that are excluded to form the subgroup are absent from the subgroup.
- the stretch breaking process of the invention is useful when blending fibers that may have already been processed to some degree, such as by incorporating color or a surface treatment that gives the fiber some visual characteristic that can be detected with the unaided eye.
- Stretch breaking is a useful way to make specialty yams without involving a lot of additional steps, such as is required in conventional staple blending where the sliver must first be prepared by chopping (cutting), blending, carding, combing, and the like as was generally illustrated at 516 and 518 in Fig. 29.
- a large quantity of feed fiber must be prepared to make the process worthwhile, since cleaning the processing equipment after each product run is very labor intensive and time consuming.
- ASTM committee E12, standard E-284 describes a means to distinguish neutral colors, such as white and beige, based on a lightness measurement with white and beige having a lightness greater than 90%. It also permits distinguishing color hue and shade to detect color difference by using CIELAB units where distinctly different colors would have a CIELAB unit difference of at least 2.0. By blending at least two different colors of fiber, where only one would have a lightness greater than 90% and the others would have a color difference in CIELAB units of at least 2.0, creates a new colored yam from at least two different feed fibers.
- FIG. 23 is a schematic elevation view of the process line of Fig. 1 that illustrates addition of an annealing zone 124a after the consolidation zone 38.
- the annealing zone was discussed previously when referring to the draw zone 124 with heating means 140 shown in Figure 8 that is used without a substantial speed change ratio.
- FIG. 24 shows a photomicrograph of a filament from a novel stretch broken product having the end 304 of each filament split as a result of the stretch breaking process.
- the feed fiber is a manmade fiber comprising continuous polyester filaments that is known by the E.I.
- the filament has a width 306 and, within that width, a plurality of thick portions 308, 310, and 312 that are connected by thin portions 314 and 316. It is believed that the stretch breaking process causes the thin portions 314 and 316 to become severed at the ends of the filaments when the filaments break. The severing occurs for a length 318 of at least about three filament widths so one or more of the thick portions, such as portion 308, are split apart from the other thick portions, such as portions 310 and 312, at the ends of the filaments. This is believed to result in the appearance and feel of having more filament ends in the yam, which improves the "hand" of a fabric made from the yam.
- Table II illustrates various products made following the teachings of the invention, in general practicing the process illustrated in Fig. 9 using the apparatus in Fig. 11.
- Feed material deniers totaling about 1,500 - 20,000 produce yams with deniers from about 100 - 400. Fibers that are drawn in the process are usually fully drawn so that the elongation to break going into the first break zone is about 10%.
- Test 1 shows a process condition for making a nylon yam having a final denier of 137. The process had a draw zone, a first break zone, a second break zone, a draft zone, and a consolidation zone similar to the process in Fig. 9.
- the feed yam came from a piddle container as at 160 in Fig.
- the consolidation jet 83a (Figs. 9 and 26) had a fluid orifice with angle 340 at 60 degrees in the direction of yam travel that was the same for all tests using this jet 83a.
- the jet exterior surface 328 is spaced from the nip between rolls 150 and 152 of roll set 148 by a distance of about 6.0 inches.
- Test 2 shows a process condition similar to test 1 which has a draw zone, a first break zone, and a second break zone approximately the same as that used to make the product illustrated in Fig. 15. The product was completed by processing the fiber further in a draft zone and a consolidation zone to form a 209 denier yam.
- Test 3 shows a product made using a polymer that has an interfilament friction coefficient less that 0.1 which is a fluoropolymer made by E. I. DuPont de Nemours & Company (hereinafter "DuPont") under the trade name Teflon ® .
- DuPont E. I. DuPont de Nemours & Company
- Teflon ® a fluoropolymer made by E. I. DuPont de Nemours & Company
- the process produced a staple Teflon product which is difficult to produce economically by other means.
- An "omega" wrap as depicted in Fig. 1 A was used on the roll sets 50a, 62a, and 148a of Fig. 11 to control slippage of the fiber in the roll sets.
- the feed fiber was supplied from a wound package 162 as in Fig. 11 (designated W in the Table II).
- the process differed from test 1 in that the fiber was not heated or drawn in the draw zone
- Test 4 shows a product made by a process similar to that illustrated in Fig. 21 where a high strength aramid fiber (DuPont trademark Kevlar ® ) was fed in upstream of the roll set 42 (42a in Fig. 11) after the polyester fiber (DuPont trademark Dacron ® ) was drawn. The aramid and polyester were then stretch broken, drafted, and consolidated together to produce a blended yam with a 397 denier. An "omega" wrap as depicted in Fig. 1 A was used on the roll sets 50a, 62a, and 148a of Fig.
- DuPont trademark Kevlar ® DuPont trademark Kevlar ®
- Test 5 shows a product made by a process similar to that in test 3 where an aramid fiber (DuPont trademark Kevlar ® ) and a fluoropolymer (DuPont trademark Teflon ® ) fiber were fed in together and were neither heated nor drawn in the draw zone; the draw zone was only used as a convenient way to transport the fibers to the first break zone. The Kevlar ® and Teflon ® were then stretch broken, drafted, and consolidated together to produce a blended yam with a 274 denier.
- aramid fiber DuPont trademark Kevlar ®
- a fluoropolymer DuPont trademark Teflon ®
- Test 6 shows a product made by a process similar to that in test 5 where an aramid fiber (DuPont trademark Kevlar ® ) and a high temperature fiber (DuPont trademark Nomex ® ) were fed in together and were neither heated nor drawn in the draw zone; the draw zone was only used as a convenient way to transport the fibers to the first break zone.
- the Kevlar ® and Nomex ® were then stretch broken, drafted, and consolidated together to produce a blended yam with a 230 denier.
- An "omega" wrap as depicted in Fig. 1 A was used on the roll sets 50a, 62a, and 148a of Fig.
- Test 7 shows a product made by a process similar to that in test 3 where an aramid fiber (DuPont trademark Kevlar ® ) was fed in and was neither heated nor drawn in the draw zone; the draw zone was only used as a convenient way to transport the fiber to the first break zone. An "omega" wrap was used. A Kevlar ® yam with a low denier of 101 was produced that would be difficult to produce economically by other means. It is believed this product has filament length characteristics similar to those of test 1.
- an aramid fiber DuPont trademark Kevlar ®
- Test 8 shows a product made by a process similar to that illustrated in test 4 except a fluoropolymer fiber (DuPont trademark Teflon ® ) was fed in upstream of the roll set 42 (42a in Fig. 11) after the polyester fiber (DuPont trademark Dacron ® ) was drawn. The fluoropolymer and polyester were then stretch broken, drafted, and consolidated together to produce a blended yam with a 278 denier. Such a product may be useful for making socks that minimize the formation of blisters on the wearer's feet. It is believed this product has filament length characteristics similar to those of test 1.
- Test 9 shows a process similar to that in test 1 except a polyester fiber is used. A yam is made having a denier of 274.
- Test 10 shows a product made by a process similar to that illustrated in Fig. 20, where a continuous filament elastic fiber (DuPont trademark Lycra ® ) was fed in upstream of the roll set 148 (148a in Fig. 11) after the polyester fiber (DuPont trademark Dacron ® ) was drawn, stretch broken, and drafted.
- the Lycra ® was tensioned to extend it about 100% before joining the Dacron ® fiber and being consolidated together, with the Lycra ® filaments remaining continuous.
- the Lycra ® contracted and created a bulky loopy yam that was highly elastic.
- Test 11 shows a process similar to that in test 9, except the polyester filaments had a cross-section like that illustrated in Fig. 25, and a 277 denier yam having split ends as in Fig. 24 was produced. It is believed this product has filament length characteristics similar to those of test 1.
- Test 12 shows a process similar to that in test 1, except the feed fiber consisted of two different fibers, each a different color. The colored fibers were combined before drawing and were drawn and stretch broken together as a single bundle of fiber. The first fiber was a distinct pink color and the second was a distinct purple color. It is believed these two colors would each be non-neutral colors having a lightness less than 90%, and they would have a color difference of at least 2.0 CIELAB units.
- Test 13 shows a process similar to test 12, except the pink colored fiber was replaced with a light gray fiber that it is believed would be a neutral color having a lightness of greater than 90%.
- the resultant yam had a color distinctly different than either of the feed colors and the yam itself had a distinct heather look.
- Test 14 shows a process similar to that of Fig. 20 where a first feed fiber of Kevlar ® was stretch broken (as in test 7) and a second fiber of continuous filament
- Kevlar ® was fed in just upstream of roll set 148a in Fig. 11.
- the continuous filaments were consolidated with the discontinuous stretch broken filaments of Kevlar to form a reinforced staple yam having a denier of 311.
- Test 15 shows a process similar to that in Fig. 22 where a Teflon fiber is fed in upstream of roll set 42 (42a in Fig. 11) (as in test 8) and a Lycra ® fiber is fed in upstream of roll set 148 (148a in Fig. 11).
- the Teflon fiber is stretch broken, and drafted with the drawn Dacron ® fiber and this blended discontinuous filament fiber is consolidated with the continuous filament Lycra ® fiber as was discussed in test 10.
- Test 16 shows a process similar to test 1 where two separate feed fibers were supplied to the process to create a large denier feed fiber of close to 20,000 denier going into the draw zone. In the draw zone two temperature zones were used on the heater 140 of Fig. 11. A first zone consisted of a 24 inch length at 100° C followed by a second zone of a 12 inch length at 188° C. A total process speed ratio of over 70X produced a yam of 277 denier. Test 17 illustrates a product made following the teachings of the invention, in particular practicing the process illustrated in Fig. 8 using the apparatus in Fig. 11.
- Fig. 11 To set up the process of Fig, 8 using the apparatus of Fig. 11 involved removing the drafting zone 144 and roll set 148a in Fig. 11 and moving the consolidation zone 38 into place adjacent roll set 62a since the process of Fig. 8 does not use a drafting zone.
- the consolidation device of Fig. 28 was used, alternatively refe ⁇ ed to as a tandem jet device, and the process was operated at a total draw of 48 to make a 192 denier product that demonstrates a low L2/L1 ratio of 0.25. Table III tabulates the tandem jet parameters.
- Test 18 is the same process as test 17 except the interlace jet of Figs. 26 and 27 was used.
- the feed yam consisted of two tows each of 6280 denier black colored nylon that were combined before the draw zone and resulted in a final yarn denier of 186.
- the process operated at a total draw of 67.4 for a high output speed of 303 ypm that is close to the speed limitations of the machine used for the test. It is expected that higher speeds exceeding 500 ypm could be achieved using the process of the invention and a higher speed machine.
- Test 19 shows results similar to test 18 where the final output speed was 269 ypm making a 198 denier Dacron® product.
- Tests 20, 21, 22, and 23 were run with a setup similar to test 17 to examine the prefe ⁇ ed distance "a" between the nozzles of the consolidation device of Fig. 28. Each test was set up to produce a yam with a different average filament length as determined by simulation. For each average filament length, several runs were made where the distance "a" between the nozzles of the consolidation device was varied by leaving the first nozzle, NI, in place at a distance of 1.72 inches to where the fluid passages intersect the fiber bore; the second nozzle was moved to various positions and a consolidated yarn sample was collected. The sample for each position was measured for strength using a Lea Product process and the strength was recorded in grams per denier for each position of the second nozzle.
- Test 20 was set up to produce a yam with an average filament length of 8.9 inches as determined by simulation. The results were plotted in Figure 35 as the curve labeled 8.9. The maximum strength occu ⁇ ed at a nozzle spacing "a" of 9.2 inches as recorded in Table III for test 20. This gave a ratio of a/avg of 1.03. A simulation of the filament distribution was also run for the conditions used in this test and are displayed in Table I for test 20. The simulation indicated the distribution of filaments greater than 1.5 times the average filament length could be expected to be 12.4%; the distribution of filaments less than 0.5 times the average filament length could be expected to be 14.7%.
- Test 21 was run the same as test 20 except the break zone lengths were changed to produce a yam made of Dacron® polyester fiber with an average filament length of 17.5 inches. This set of conditions also was run with a high L2/L1 ratio of 0.58. The results were plotted in Figure 35 as the curve labeled 17.5. The maximum strength occu ⁇ ed at a nozzle spacing "a" of 13.0 inches as recorded in Table III for test 21. This gave a ratio of a/avg of 0.74. A simulation of the filament distribution was also run for the conditions used in this test and are displayed in Table I for test 21.
- Test 22 was run the same as test 20 except the break zone lengths were changed to produce a yam made of Dacron® polyester fiber with an average filament length of 6.4 inches. The results were plotted in Figure 35 as the curve labeled 6.4. There was not a distinct value for the maximum strength; the curve was essentially flat except for a dip down to a strength of about 0.8 which was an estimated value since the sample made at this distance of about 4 inches was so weak a full size skein could not be wound for the standard Lea Product test.
- This product made with a single break zone has product characteristics that fall outside the limits of the invention using two break zones, but it shows that the nozzle spacing has an optimum value for best yam strength and the nozzle spacing invention is effective with a variety of processes that make a yam with an average filament length greater than 6 inches.
- the value for the spacing "a" between the first nozzle and second nozzle ranges from 0.74 to 1.53 , or about 0.5 to 2.0 times the average filament length for fibers/yams with an average filament length greater than about 6.0 inches. Taking the three values of "a” and averaging them, the prefe ⁇ ed value for "a” is about 1.1 times the average filament length.
- Test 24 was run with a setup similar to test 17 using the consolidation device of Fig. 28 and the L2/L1 ratio was run at 0.35 to produce a yam with an average filament length of 6.7 inches.
- Test 25 uses a process similar to that in test 17.
- the feed material in test 21 is a bicomponent elastic yarn wherein each filament has a circular cross section with one half of the cross-section comprising 2GT polyester and the other half cross-section comprising 3GT polyester.
- a feed material is described in U.S. Patent 3, 671, 379 to Evans et al., hereby inco ⁇ orated herein by reference.
- Related patents to others are U.S. Patent Nos. 3,562,093; 3,454,460; and 2,439, 815.
- the two different polymers in the cross-section have different shrinkage characteristics after spinning so that after heat treatment, the fiber becomes a crimped fiber where the filaments curls into a coiled springy structure.
- the fiber Before heat treatment to activate the fiber latent elasticity, the fiber still has a significant amount of elasticity or crimp, which has caused a problem in the past making staple yam using conventional combing and carding equipment.
- staple yam of bicomponent fiber is not known in the textile trade.
- the resultant multifilament yam is very springy and has a substantial elasticity from no tension to a maximum tension, where all the elasticity is removed without plastic deformation of the filaments.
- This elasticity is characterized as percent crimp development, CD, that can be developed with wet heat and measured following the guidelines in the '379 and '460 reference above.
- the finished yam must be heat treated after stretch breaking to recover its latent elasticity and obtain its final elastic characteristics.
- Test 25 shows a process condition for making a bicomponent yam of 2GT polyester and 3GT polyester components (designated BC23) having a final denier of 160.
- the process has a heat treating zone, a first break zone, a second break zone, and a consolidation zone similar to the process in Fig. 8; a draft zone is not used.
- the feed yam comes from 12 wound packages of 100 denier yam each similar to 162 in Fig. 11.
- the feed yam is pre-drawn, but has not been heat treated to develop the latent elasticity of the fiber, although the fiber possesses some partial elasticity or crimp.
- the final yam product was wound up on a winder 222 shown in Fig. 11.
- the consolidation device used is the tandem jet type in Fig 28.
- the tensioner at 164 was adjusted to provide enough tension on the feed yam so that all of the partial stretch (crimp) was removed from the feed yam at roll 168.
- the yam is heated treated to a temperature of 180° C by fiber heater 140 while maintaining tension, but without drawing the filaments. Although the fiber was not drawn in draw zone 124, it was surprisingly necessary to heat the fiber to maintain good operability in the break zones.
- the yam was stretch broken and rebroken in zones Dl and D2 and was then forwarded to the consolidation jet 83b without drafting to form a yam of 160 denier. The yam was then wound on a package as at 222 with enough tension that the stretch in the yam was substantially removed.
- the yam To develop the elastic character of the yam it is necessary for the yam to undergo heating to about 100 degrees C to form a helically coiled elastic yam structure (having crimp and curl) having good bulk and elastic recovery. Such heating may be accomplished in a separate step or the yam may be woven into a fabric and the heat supplied by the dying process for the fabric.
- the crimped discontinuous filament yarn is believed to have a crimp development of from about 35-40% as measured according to the procedure described in the '379 referenced patent to Evans et al.
- Test 26 shows a process condition for making a bicomponent yam of 2GT and 3GT components (BC23) with a 50:50 ratio of components and the consolidated yam having a final denier of 176.
- the process has a drawing and heat treating (annealing) zone, a first break zone, a second break zone, and a consolidation zone similar to the process in Fig. 8; a draft zone is not used.
- the feed yam comes from 24 wound packages to make up a 4714 denier undrawn yam.
- the final yam product was wound up on a winder as at 222 in Fig. 11.
- the consolidation interlace jet 83a (Fig. 26 and 27) had a fluid inlet orifice angled at 60 degrees in the direction of yam travel.
- the tensioner at 164 was adjusted to provide enough tension on the feed yam so that all of the stretch was removed from the feed yam at roll 168.
- the yam is drawn at a temperature of 160° C by fiber heater 140 while undergoing a draw ratio of 3. OX.
- the yam was stretch broken and rebroken in zones Dl and D2 and was then forwarded to the consolidation jet 83a without drafting to form a yam of 176 denier.
- the yam was then wound on a package as at 222 (Fig. 11). If the yam was heat treated with (hot air or) steam to raise the temperature to 100° C which would served to redevelop the shrinkage and curl in the filaments the yam would be expected have a CD of about 50-60%.
- a biconstituent fiber is typically one with a core polymer that is highly elastic (or "soft"), such as a Lycra® elastomer, that has "wings" of an inelastic ("hard”) polymer attached as longitudinal ribs during the spinning process.
- the latent elasticity of the fiber can be activated by heat that causes the soft core polymer to shrink considerably more than the hard wing polymer which causes the composite structure to helically coil up to look like a screw thread.
- This fiber structure also has some "crimp" after spinning and drawing and before heat treating, similar to the bicomponent fiber.
- Polymer pairs should be compatible so they stick together, and can be cospun. For that, they have to have a similar thermal response and functional spinning viscosity. Useful pairs are therefore usually pretty similar chemically, or have some specific interaction.
- Common bicomponents are two polyesters, two nylons, etc., while the biconstituents are e.g.
- 4GT/4GT-4GO HYTREL®
- nylon/PEBAX® homopolymer/block copolymer pairs in which one block of the copolymer is the same as the homopolymer. Ratios can vary considerably, but are generally limited to somewhere between 80/20 and 20/80, preferably 70/30 to 30/70.
- Other conventional crimped fibers, such as those crimped by jets, gear crimpers, stuffer box crimpers and the like could also be converted to a staple yam using the process of the invention.
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Abstract
Description
Claims
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2003/033696 WO2005049902A1 (en) | 2003-10-21 | 2003-10-21 | Yarn |
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EP03776527A Withdrawn EP1675980A1 (en) | 2003-10-21 | 2003-10-21 | Yarn |
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AU (1) | AU2003284345A1 (en) |
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Publication number | Priority date | Publication date | Assignee | Title |
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GB924086A (en) * | 1958-04-04 | 1963-04-24 | Du Pont | Improvements in composite textile yarns and in processes for their production |
GB1058551A (en) * | 1962-09-07 | 1967-02-15 | Courtaulds Ltd | Improvements in and relating to the production of bulky yarns |
US4403470A (en) * | 1981-12-30 | 1983-09-13 | E. I. Du Pont De Nemours And Company | Process for making composite yarn of continuous filaments and staple fibers |
TW317578B (en) * | 1994-03-01 | 1997-10-11 | Heberlein & Co Ag | |
DE10161419A1 (en) * | 2001-12-13 | 2003-06-18 | Temco Textilmaschkomponent | Method and device for producing a combination yarn |
-
2003
- 2003-10-21 AU AU2003284345A patent/AU2003284345A1/en not_active Abandoned
- 2003-10-21 WO PCT/US2003/033696 patent/WO2005049902A1/en active Application Filing
- 2003-10-21 EP EP03776527A patent/EP1675980A1/en not_active Withdrawn
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AU2003284345A1 (en) | 2005-06-08 |
WO2005049902A1 (en) | 2005-06-02 |
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