EP1877601B1 - Melt spinning method for producing a composite yarn as well as a composite yarn - Google Patents

Melt spinning method for producing a composite yarn as well as a composite yarn Download PDF

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Publication number
EP1877601B1
EP1877601B1 EP05797782A EP05797782A EP1877601B1 EP 1877601 B1 EP1877601 B1 EP 1877601B1 EP 05797782 A EP05797782 A EP 05797782A EP 05797782 A EP05797782 A EP 05797782A EP 1877601 B1 EP1877601 B1 EP 1877601B1
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EP
European Patent Office
Prior art keywords
yarn
poy
hoy
filaments
composite
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.)
Not-in-force
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EP05797782A
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German (de)
English (en)
French (fr)
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EP1877601A1 (en
Inventor
Suprit School of Textile Design & Fashion SINGH
Markus Reichwein
Ulrich Enders
Klaus Schäfer
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Oerlikon Textile GmbH and Co KG
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Oerlikon Textile GmbH and Co KG
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Publication of EP1877601A1 publication Critical patent/EP1877601A1/en
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/082—Melt spinning methods of mixed yarn
    • 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
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/18—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by combining fibres, filaments, or yarns, having different shrinkage characteristics

Definitions

  • the invention relates to a melt spinning method for producing a composite yarn as defined in the preamble of claim 1, as well as a composite yarn as defined in the preamble of claim 15.
  • effect yarns which exhibit special yarn effects, such as, for example structure effects, glaze effects, or color effects.
  • yarn effects can be produced by blending dissimilar synthetic fibers.
  • a method of this type is disclosed, for example, in US 5,980,355 or US 5,943,852 .
  • the dissimilar fibers are extruded in a spinning process and combined to a composite yarn in a single stage.
  • the invention proceeds from this variant of producing a composite yarn.
  • two filament bundles are extruded side by side from a polymer melt, for example, a polyester. After extruding, one of the filament bundles is cooled and drawn in such a manner that a POY yarn with a preoriented molecular structure is formed. The parallel extruded second filament bundle is cooled and drawn in such a manner that an HOY yarn forms with a highly oriented molecular structure. After cooling and drawing, the two yarns are combined to a composite yarn.
  • Composite yarns of this type distinguish themselves by a high shrinkage difference in the fibers, since a POY yarn has a high boiling water shrinkage, and an HOY yarn has a relatively low boiling water shrinkage in the fibers. These composite yarns are especially suited for producing structure effects, such as, for example, bulkiness.
  • US 5,858,290 discloses a melt spinning method for producing a composite yarn, wherein two filament bundles are extruded parallel in side-by-side relationship, and cooled under identical conditions, so that after cooling two POY yarns form with a preoriented molecular structure. Before combining the two yarns, one of the yarns is fully drawn, so that an FOY yarn forms. The POY yarn and the FOY yarn are then combined to the composite yarn.
  • the fiber differences which originate from drawing have the disadvantage that the limited withdrawal speed of a POY yarn permits producing only very limited differences in the physical properties of the fibers.
  • DD 266 598 A1 discloses a method of producing a composite yarn, wherein the filament bundles advance through different setting zones directly after extruding and before cooling. In this process, the action of a so-called.afterheater is used to attain a delayed crystallization in one of the filament bundles. After a joint cooling, the filament bundles are combined and wound as a composite yarn to a package. Likewise, this process permits producing different physical properties in the individual fibers only within relatively narrow limits. Thus, the composite yarns disclosed in US 5,858,290 and DD 266 598 A1 are limited to a maximum shrinkage difference in the fibers of at most 30%.
  • EP-A-1 361 300 discloses a method for manufacturing polyester mixed fiber yarn by melt-extruding a polyester composition A which comprises a substrate polymer comprising a polyester and 0,5 to 5,0 percent by weight of a polymer P being different from the substrate polymer.
  • the object of said document is to provide a method for stably producing a polyester blended yarn which comprises two or more filament groups having different elongations, giving a woven or knitted fabric exhibiting a higher-grade texture than those of conventional fabrics and being excellent in post processability.
  • US-B1-6 723 265 relates to a method for producing polyester-based combined filament yarn, wherein a polymer different from a base polymer comprising a polyester component in an amount within the range of 0,3 to 5,0 percent by weight based on the base polymer is added to the base polymer.
  • the filaments of the yarn are taken off at a speed of 2.500 m/min or above, wherein a spinneret hole diameter of a filament group without being subjected to a heat treatment is 1,5 times or above a spinneret hole diameter of a filament group in a open state subjected to a heat treatment.
  • JP-A-10 298839 discloses a method for producing a yarn for a fabric having light weight and spun-like fuzzy feeling although having high density.
  • the combined filament yarn is composed of a HOY yarn A and a polyester-based slightly shrinkable yarn B having a lower hot water shrinkage percentage than yarn A.
  • WO-A1-93 10292 relates to a process for improving the properties of a mixed shrinkage yarn of spin-oriented polyester filaments of elongation-to-break 40 to 120 percent comprising polyester filaments of high boil-off shrinkage greater than 15 percent and of low shringage polyester filaments.
  • the mixed shrinkage yarn is cold-drawn without heat-setting to provide drawn filaments of elongation-to break less than 30 percent from drawing said filaments of high boil-off shrinkage, and wherein said low shrinkage filaments are of tenacity at 7 percent elongation at least 0,7 grams/denier, boil-off shrinkage less than 10 percent, thermal stability as shown by an value less than +1 percent, net shrinkage less than 8 percent, maximum shrinkage tension less than 0,3 grams/denier, density 1,35 to 1,39 grams/cubic centimeter, and crystal size 55 to 90 Angstroms and also at least (250p - 282,5) Angstroms.
  • a special object of the invention consists in attaining as much as possible for each desired yarn effect an optimum of the fiber blend in the composite yarn.
  • this object is accomplished by a melt spinning method with the steps of claim 1, as well as by a composite yarn with the features of claim 15.
  • the invention is based on the knowledge that the blending ratio of the fibers in the composite yarn as well as the fiber cross sections are decisive for defining the characteristic and thus the possible application of the composite yarn.
  • limit values have crystallized for the application in the textile field, which are to be maintained for adjusting the yarn effects that are common for textile applications.
  • the filaments of the POY yarns and the filaments of the HOY yarns are thus combined in the composite yarn at a mass ratio of M POY /M HOY ⁇ 2.5.
  • the filaments of the POY yarn have a denier ⁇ 2.0 deniers
  • the filaments of the HOY yarn have a denier of ⁇ 4.0 deniers, preferably ⁇ 1.5 deniers.
  • the composite yarn with different mass percentages of the POY yarn and HOY yarn.
  • the ranges of the mass ratio of M POY /M HOY from 1.0 to 2.5 are especially suited for producing structure effects and color effects in the composite yarn.
  • a range of the mass ratio of M POY /M HOY from 0.5 to 0.75 has also been found very advantageous.
  • the further development of the method according to the invention is especially preferred, wherein the POY yarn and the HOY yarn are each formed from a different number of filaments in the filament bundle with different deniers of the filaments. With that, it is possible to realize individual combinations between the POY yarns and the HOY yarns.
  • An essential aspect in the melt spinning process of a composite yarn is the combination of the POY yarn and the HOY yarn.
  • the variant of the method has shown especially useful, wherein the composite is produced by a multistage entanglement, with a first stage occurring in an initial entanglement after cooling, and a second stage by a main entanglement before winding the composite yarn.
  • the initial entanglement occurring after cooling has the advantage that the POY yarn and the HOY yarn can jointly advance in the spinning process for their further treatment, without producing an overly intensive yarn cohesion. Only before winding, will a main entanglement take place, which causes the two yarns to combine by means of entanglement knots.
  • an adequate yarn cohesion will advantageously be reached, when the main entanglement is performed under an overpressure of the air, which permits producing in the composite yarn at least a number of 25 entanglement knots per meter.
  • the filaments of the POY yarn are lubricated after cooling and advancing through a spin zone ⁇ 800 mm.
  • a greater spin zone of the POY yarn enables a slower cooling, which is accompanied by an increase of the withdrawal speed.
  • the filament bundle of the POY yarn and the filament bundle of the HOY yarn are withdrawn at the same withdrawal speed.
  • an advantageous further development provides for adjusting cooling and withdrawal of the filament bundle of the POY yarn such that a boiling water shrinkage results of at least 50%, preferably in ranges from 50% to 70%.
  • the cooling and withdrawal of the filament bundle of the HOY yarn are adjusted such that a boiling water shrinkage results in the yarn of at most 10%, preferably in a range from 4% to 10%. With that, it is possible to realize boiling water shrinkage differences in the composite yarn of ⁇ 40%, preferably ⁇ 45%.
  • the composite yarn is wound to a package, with the takeup speed being adjusted only insignificantly higher than the withdrawal speed.
  • the takeup speed differs from the withdrawal speed only by a factor in a range from 0.95 to 1.2.
  • the composite yarn of the invention distinguishes itself as effect yarn for textile applications.
  • the composition of the POY yarn and the HOY yarn in accordance with the invention permits generating in the composite yarn both structure effects and color effects in a particularly intensive way.
  • the similar crystalline structure of the POY yarn and the HOY yarn is especially advantageous during a subsequent dyeing of the composite yarn.
  • the filaments of the composite yarn absorb dyes with the same intensity, so that no color differences develop within the composite yarn.
  • the filament deniers of the HOY yarn are in a range of ⁇ 1.5 deniers.
  • Color effects such as, for example, a mixed color effect, can be very advantageously produced by the mass ratio M POPY /M HOY in a range from 1.5 to 2.0 or, alternatively, also in a range from 0.5 to 0.75.
  • the composite yarn of the invention distinguishes itself in particular by the high shrinkage difference in the filament, so that so-called flat effects can be produced with high shrinkage differences of more than 40%.
  • the composite yarn of the invention opens totally new possibilities for textile applications, which have so far been reserved only to composite yarns that were produced by the two-stage process.
  • the filaments of the POY yarn and the HOY yarn are interconnected by a high number of entanglement knots. In this connection, it is absolutely necessary to maintain a lower limit value of 25 entanglement knots per meter.
  • FIG. 1 is a schematic view of the setup of a spinning apparatus.
  • the spinning apparatus comprises a POY spinning position 1 as well as an HOY spinning position 2, which are arranged side by side with no space inbetween.
  • the spinning position 1 includes a driven spin pump 1.1 which connects to a source of melt not shown.
  • the spin pump 1.1 connects to a spinneret 1.2.
  • the spinneret 1.2 which experts also name spin pack is arranged in a heatable spin head 1.3. On its underside, the spinneret 1.2 comprises a plurality of spin holes (not shown). Downstream of the spin head 1.3, a cooling device 1.4 extends.
  • the construction of the cooling device 1.4 within the POY spinning position is basically disclosed in DE 101 16 294 A1 , so that this publication is herewith incorporated by reference.
  • the special feature of the cooling device 1.4 is that the filament strands are cooled by means of a cooling tube, in which a cooling air stream generated in the direction of the advancing yarn cools the filament bundle as much as possible free of stress.
  • a yarn lubrication device 1.5 is provided for combining the cooled filaments to a POY yarn 3.
  • the HOY spinning position 2 comprises likewise a driven spin pump 2.1, which connects to a source of melt. In the production of the composite yarn from a polymer melt, it is common to connect the spin pumps 1.1 and 2.1 to an extruder.
  • the spin pump 2.1 connects to a spinneret 2.2, which comprises on its underside a plurality of spin holes for extruding a plurality of filament strands.
  • the spinneret 2.2 is arranged in a heatable spin head 2.3. Downstream of the spin head 2.3, a cooling device 2.4 extends, and at the outlet end of the cooling device 2.4, a yarn lubrication device 2.5 follows.
  • the construction of the cooling device is likewise disclosed in DE 101 16 294 A1 , so that for the description of the cooling device, the foregoing publication is herewith incorporated by reference.
  • the cooling device 2.4 is operated separately and independently from the cooling device 1.4, so that the filaments produced in the HOY spinning position 2 are differently cooled than the filaments spun in the POY spinning position 1.
  • the spin zone in which the filaments are cooled, is made, because of process conditions, substantially shorter in the HOY spinning position 2 than in the POY spinning position 1.
  • the spin zone is identified by the distance of the yarn lubrication devices 1.5 and 2.5 from the respective undersides of spinnerets 1.2 and 2.2.
  • the spin zone has a length of at least 800 mm. Preferably, it is made longer than the spin zone of the HOY spinning position 2, which has a maximum length of 900 mm.
  • the yarn lubrication device 2.5 combines the filaments to an HOY yarn 4.
  • the POY yarn 3 and the HOY yarn 4 are withdrawn by a godet unit 7, which comprises a driven withdrawal godet 8 and a guide roll 9.
  • the HOY yarn 4 advances downstream of the yarn lubrication device 2.5 over deflection rolls 5.1 and 5.2 into the path of the advancing POY yarn 3.
  • deflection rolls 5.1 and 5.2 it is preferred to use freely rotatable rolls, preferably supported in air bearings, to generate the least possible yarn frictions.
  • Downstream of the deflection roll 5.2 is a first entanglement unit 6.
  • the first entanglement unit 6 comprises a yarn channel, through which the POY yarn 3 and the HOY yarn 4 advance jointly.
  • the yarn channel receives compressed air for entangling the filaments of the two yarns, so that in a first stage, a yarn cohesion occurs for forming a composite yarn 10.
  • the composite yarn 10. advances over a subsequent draw godet 12 by partially looping same.
  • a main entanglement unit 11 extends, in which the filaments of the composite yarn 10 receive a final yarn cohesion.
  • the composite yarn 10 enters a takeup device 13, and is wound to a package 14.
  • the takeup device 13 is constructed as a winding machine with a turret, as is disclosed, for example, in EP 0 937 008 B1 . With this type of takeup, it is possible to wind the composite yarn to packages in a continuous operation.
  • the foregoing publication is herewith incorporated by reference.
  • the spinnerets 1.2 and 2.2 are selected with respect to the number of their spin holes and choice of the capillary diameters of the spin holes such that a defined mass ratio of the mass of the POY yarn M POY to the mass of the HOY yarn M HOY adjusts in the composite yarn.
  • the spin holes of the spinneret 1.2 have a capillary diameter of at least 0.25 mm to be able to produce a filament denier in the POY yarn of ⁇ 2 deniers.
  • the spin holes of the spinneret 2.2 are made smaller to be able to produce, for example a filament denier in the HOY yarn of 1.5 deniers.
  • Both the mass of the POY yarn 3 and the mass of the HOY yarn 4 are determined by the denier that results after withdrawing the filaments, and the number of the respective filaments.
  • the spinnerets 1.2 and 2.2 may be made different both with respect to their number of spin holes and the size of the capillary diameters.
  • the mass ratio that is decisive for the composite yarn is selected as a function of the yarn effect that is to be produced in the composite yarn.
  • a source of melt supplies a polymer melt, which is delivered by the spin pump 1.1 to the spinneret 1.2 and by the spin pump 2.1 to the spinneret 2.2.
  • the spin pumps 1.1 and 1.2 are adapted to the respective constellation of the spin holes in the spinnerets 1.2 and 2.2 as well as the selected withdrawal speed.
  • the method of the invention requires maintaining a spin zone of at least 800 mm during the cooling of the POY yarn. It is preferred to select a still longer spin zone for a stressfree cooling of the filaments of the POY yarn.
  • the filament strands of the HOY yarn are cooled in a spin zone that is shorter than 900 mm.
  • the spin zone for producing the HOY yarn 4 is shorter than the spin zone of the POY yarn 3.
  • the entanglement by the first entanglement unit 6 is adjusted such that the filaments undergo a slight entanglement, so as to not impede the formation of the POY yarn with a partially oriented molecular structure, and the formation of the HOY yarn with a highly oriented molecular structure.
  • the withdrawal speed of the withdrawal godet unit 7 is adjusted to values above 3,500 m/min. With a corresponding cooling of the POY yarn, it is possible to achieve withdrawal speeds greater than 5,000 m/min.
  • the final combination of the filaments of the POY yarn and the HOY yarn to the composite yarn proceeds in the main entanglement unit 11 after withdrawal by the godet unit 7.
  • the compressed air entering the yarn channel of the main entanglement unit 11 is adjusted to an overpressure, which leads to an intensive knot formation. It is thus possible to produce in the composite yarn a minimum number of 25 knots per running meter.
  • the main entanglement of the composite yarn 10 occurs between the godet unit 7 and the draw godet 12.
  • the draw godet 12 is driven at a somewhat higher circumferential speed than the withdrawal godet 8, so that a predefined yarn tension can be adjusted for the entanglement.
  • the composite yarn 10 is wound by the takeup device 13 to a package 14.
  • the composite yarn 10 is wound at a takeup speed, which is only insignificantly higher than the withdrawal speed, so as to prevent unacceptable drawing.
  • the takeup speed is adjusted to differ from the withdrawal speed by a factor of 0.95 to 1.2.
  • the cooling devices 1.4 and 2.4 may include modifications, in which the filaments strands first advance through a first uncooled heating zone.
  • so-called annealers may be arranged between the cooling device 2.4 and the spin head 2.3 in order to produce an especially low-shrinkage HOY yarn.
  • the combination of the composite yarn 10 can be further improved before the takeup by arranging a third entanglement unit between the draw godet 12 and the takeup device 12. With that, it is possible to achieve in a third stage a further entanglement of the filaments that is directed in particular to the yarn lengths forming between the knots.
  • the composite yarn of the invention that is produced by the method of the invention is thus especially suited for use in textile applications as a effect yarn with a structure effect or a color effect.
  • a mass ratio of the filaments of the POY yarn and the HOY yarn is selected. In so doing, it is necessary to maintain certain filament deniers of the POY yarn and the HOY yarn respectively, to ensure on the one hand a strength of the yarn as is required for its application, and to obtain on the other hand the desired effects in structure or color.
  • the composite yarn of the invention is therefore defined by limit ranges of the filament deniers.
  • the filaments of the POY yarn have a denier ⁇ 2.0 deniers, and the filaments of the HOY yarn a denier ⁇ 4.0 deniers, preferably ⁇ 1.0 denier. In so doing, it is necessary to maintain a mass ratio of the filaments of the POY yarn to the filaments of the HOY yarn of M POY /M HOY ⁇ 2.5. In the case of larger mass ratios, there is no adequate guarantee for the properties as are required for textile yarns.
  • Table 1 lists a plurality of typical composite yarns, which were produced by the method of the invention.
  • the composite yarns are within a total denier range from 135 denier to 450 denier, with the number of filaments being at least 60 and at most 168.
  • the composite yarns listed in Table 1 were extruded from polyester. They are especially suited for producing a so-called flat effect with a high shrinkage difference. In all combinations, the boiling water shrinkage measured on the filaments of the POY yarn ranged from 50 to 70%.
  • the HOY yarn with a low boiling water shrinkage in a range from 4 to 10%, so that it was possible to adjust shrinkage differences of more than 60%.
  • the takeup speeds were set in a range from 4,500 to 6,500 m/min.
  • Tables 2 and 3 show further embodiments of the composite yarn according to the invention, which were likewise extruded from a polyester material.
  • the composite yarns listed in Table 2 are preferred and suited to produce a so-called wooly effect.
  • the composite yarn is textured in a further processing step, wherein individual breaks of the filaments of the HOY yarn occur. With that, a surface is created, which is similar to a wool yarn.
  • the mass ratio M POY /M HOY be preferably in a range from 1.0 to 1.5.
  • the filament deniers of the HOY yarn are preferably ⁇ 1.5 deniers.
  • the composite yarn of the invention is also particularly suited for dyeing. Because of similar crystallinity of the POY yarn and the HOY yarn, it is possible to achieve an intensive coloring. It is likewise possible to adjust special color effects, such as, for example, a mixed color effect. To do so, it has been found that the mass ratio M POY /M HOY should be in a range from 1.5 to 2.0, or alternatively in a range from 0.5 to 0.75. In this respect, the composite yarn can be used for textile applications in many ways. The combination between a POY yarn and an HOY yarn can be realized by the use of one polymer type, or also by the use of different modifications of a base polymer or a plurality of polymer types.
  • the method of the invention distinguishes itself in particular by high withdrawal speeds and a thus accompanying high productivity in the production of a composite yarn in a single stage process. Likewise, the expenditure for processing units is advantageous, in particular in the takeup region, since both parallel spun yarns are jointly withdrawn at the same withdrawal speed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
EP05797782A 2005-03-09 2005-09-23 Melt spinning method for producing a composite yarn as well as a composite yarn Not-in-force EP1877601B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102005010742 2005-03-09
PCT/EP2005/010309 WO2006094538A1 (en) 2005-03-09 2005-09-23 Melt spinning method for producing a composite yarn as well as a composite yarn

Publications (2)

Publication Number Publication Date
EP1877601A1 EP1877601A1 (en) 2008-01-16
EP1877601B1 true EP1877601B1 (en) 2012-04-25

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EP05797782A Not-in-force EP1877601B1 (en) 2005-03-09 2005-09-23 Melt spinning method for producing a composite yarn as well as a composite yarn

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EP (1) EP1877601B1 (zh)
KR (1) KR20070110342A (zh)
CN (1) CN101137775B (zh)
WO (1) WO2006094538A1 (zh)

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WO2012007333A1 (de) 2010-07-10 2012-01-19 Oerlikon Textile Gmbh & Co. Kg Verfahren und vorrichtung zur herstellung eines verbundfadens
CN103403234B (zh) 2011-02-24 2016-06-29 欧瑞康纺织有限及两合公司 用于熔融纺丝的设备
CN102560777A (zh) * 2011-07-25 2012-07-11 桐乡市中辰化纤有限公司 复合异收缩丝生产方法
KR101367037B1 (ko) * 2012-05-30 2014-02-25 한국섬유개발연구원 심색성, 신축성 및 형태안정성이 우수한 편직물
CN105332073B (zh) * 2015-11-02 2017-11-10 北京中丽制机工程技术有限公司 一种三组分全拉伸丝纺丝系统
CN105525374B (zh) * 2015-11-02 2017-12-19 北京中丽制机工程技术有限公司 一种双组分全拉伸丝纺丝系统

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JPH10298839A (ja) 1997-04-23 1998-11-10 Unitika Ltd 高収縮性軽量嵩高加工糸
JP2000220031A (ja) * 1999-01-25 2000-08-08 Teijin Ltd ポリエステル混繊糸の製造法
CN1297700C (zh) * 2000-12-20 2007-01-31 帝人株式会社 生产聚酯混合纤维纱的方法
DE10116294A1 (de) * 2001-03-31 2002-10-10 Barmag Barmer Maschf Verfahren zm Schmelzspinnen eines Verbundfadens und Spinnvorrichtung

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A. ZIABICKY & H. KAWAI: "High-Speed Fiber Spinning", 1985, JOHN WILEY & SONS, New York (US), ISBN: 0-471-89792-2, article T. KAWAGUCHI: "Industrial Aspects of High-Speed Spinning", pages: 3 - 19 *
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SYANG-PENG RWEI: "Modification of PET in High-Spped Melt Spinning by Blending with PEN", POLYMER ENGINEERING AND SCIENCE, January 2000 (2000-01-01) *

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KR20070110342A (ko) 2007-11-16
CN101137775B (zh) 2010-08-18
CN101137775A (zh) 2008-03-05
EP1877601A1 (en) 2008-01-16
WO2006094538A1 (en) 2006-09-14

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