JPS6252056B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for producing a three-dimensional curl filament, and particularly to an improved method and apparatus for producing a three-dimensional curl filament made of synthetic fibers used as a raw material for locking material for cushioning materials. be.

Conventionally, filaments have usually been bidirectional, so even if the intersections of the filaments are bonded with an adhesive, there has not been much increase in rebound or improvement in cushioning properties. Further, when attempting to form a three-dimensional curl, the curl is mainly formed only around a part of the core, so that the desired three-dimensional curl cannot be formed. Furthermore, with conventional curling devices that perform false twisting, the single yarn denier is thin, and the maximum total denier is mechanically limited.
The limit was 2000 denier, which meant that only small curls could be formed.

In order to improve these drawbacks of the conventional equipment, we have developed a system that is equipped with a heating device using moist heat just before processing, and a false twisting device for two consecutive rope twists: the first normal twist and the second round twist. In the meantime, a strong heating device is installed to heat-set the large and small double spiral crimp on the thermoplastic filament, and then the false twist is removed and the continuous single yarn is cut into a thick several hundred deniers by the cutting device. A continuous manufacturing device for synthetic fiber crimped staples for cushion materials has been proposed (Public Act No. 49-40402).
Publication No.). However, this device has a drawback in that it does not have sufficient effect on the product by preventing the rough twisting in the second twisting step from spreading to the first ordinary twisting step.

In order to eliminate such conventional drawbacks, the present inventor first developed a tension driving means and a plurality of single-stranded strands provided in front of the tension driving means and tensioned and transported by the tension driving means. a guide roller having a group of U-shaped grooves that rotates so as to exert opposite effects on the filament at the front and rear; a pair of rotating grooved rollers provided in front of said group of rollers with non-stop means for pulling said double-twisted filament at a transport speed and distance sufficient to form and complete heat setting; a heating means for the filament in which the double twist has been formed; a group of plural single twist transfer rollers provided in front of the twisting means for applying a required rotational tension to form a single twist and guiding the filament; We have discovered a device comprising double twist spread stopping means provided on the rearmost roller of the roller group (Japanese Patent Application Laid-Open No. 144448/1982). However, the above-mentioned equipment can only manufacture within a narrow range of total denier, and it is difficult to adjust the double twisting process and transfer speed to the total denier.
For this reason, processing operations are also complicated and workability is low.

Therefore, the object of the present invention is to create three-dimensional curls, that is, three-dimensional curls, which, when made into a locking material or incorporated into a cushioning material, make the greatest contribution to increasing the repulsion elastic force and improving the cushioning properties. An object of the present invention is to provide a method for producing a three-dimensional curl filament and an apparatus therefor, which can impart a three-dimensional curl to a fiber filament.

Another object of the present invention is a method and an apparatus for forming three-dimensional curl filaments, which can be produced in a wide range of total deniers, and which separate double twist processing and tension speed adjustment to facilitate processing operations. Our goal is to provide the following.

For these purposes, the diameter at the bottom of the groove is 10~
A plurality of thick denier filaments are placed between a grooved first free roller having a diameter of 500 mm and at least one other second free roller.
5,000 to 3,000,000, and a single twisting process in which the filament is made to form a single twist by applying twisting force in the subsequent double twisting process, and forming while forming a double twist in the filament from the starting point after passing through the single twisting process. A double-twisting step in which the double-twisted filament is heated by passing it through a cylindrical guide means, and the formed double-twisted filament is cooled while applying a twisting force to give the filament a double twist. a cooling process to complete heat setting; an untwisting process to form a three-dimensional curl filament by untwisting the double-twisted filament thus heat-set while being pulled by a tension drive roller; This is achieved by a method for manufacturing a three-dimensional curl filament comprising a cutting step for cutting the three-dimensional curl filament.

The method includes a means for cutting the untwisted filament, a plurality of tension drive rollers disposed in series for tensioning and untwisting the cooled double-twisted filament, and a plurality of tension drive rollers in front of the tension drive rollers. A twisting force is applied to a filament comprising a plurality of grooved rollers rotatably pivoted between two rotary plates with a filament passage hole bored in the center of rotation near the periphery. and means for cooling the formed double-twisted filament, cylindrical guide means for the double-twisted filament provided in front of the roller group, and heating for the formed double-twisted filament. means, and a groove provided in front of the guide means and having a diameter of 10 mm at the bottom of the groove.
A grooved free roller of ~500 mm and at least one other free roller form a single twist while preventing the double twist from spreading to the filament at a certain point by the twisting force in the double twisting process. This is achieved by a three-dimensional curl filament manufacturing apparatus comprising a single twisting means.

The filaments used in the present invention include synthetic fibers and natural fibers such as polyester, polyamide, polypropylene, polyacrylonitrile, polyvinylidene chloride, vinylon, etc. Synthetic fibers are preferred, with polyester fibers being the most preferred. . In other words, polyester filament has better rigidity and greater repulsion than other synthetic fibers, and as will be described later, when a cushion material is used in the form of a locking material, an extremely good cushioning material can be obtained. . Therefore, the filaments used in the present invention have a monofilament of 20 to 3000 denier, preferably 50 to 1000 denier, most preferably 150 to 600 denier, and a total denier of 5000 to 3000000 denier, preferably 50000 denier.
~2000000 denier, most preferably 100000~
It is 1000000 denier.

The three-dimensional curl filament obtained by the present invention can be incorporated into a cushioning material alone after cotton manufacturing to improve cushioning properties and rigidity, or it can be formed into a predetermined shape by joining and locking the intersections of the filament with an adhesive. A locking material is formed and used alone as a cushioning material or incorporated into another cushioning material to improve cushioning properties and rigidity.

Next, the present invention will be explained in detail with reference to the drawings. As shown in FIGS. 1 to 5, a filament supply port 1, a group of single twist transfer rollers 2, a guide means with heating means 3, a twisting force applying and cooling means 4, a tension drive roller 6, and tension and cutting rotations are synchronized. Filament cutting means 5 are arranged in sequence in the filament feeding direction. Next, each device will be explained in detail.

A plurality of filaments F, which are almost uniformly bundled at the filament supply port 1, are stretched over rollers 2 for a single twisting process. The rollers 2 include a first roller 2a with a groove and which can rotate freely, and at least one other second roller 2b which can rotate freely.
It becomes more. Although it is desirable that the second roller 2b has a groove, it is not necessary to provide the groove. If necessary, other rollers may be provided in addition to the second roller 2b, but as shown in FIG. 1 and FIG. They may be provided coaxially instead of the rollers, and it is usually desirable to provide three to four or more on each roller. The coaxial rollers must each have the same diameter. Therefore, the filament F has a double twist Fd formed in a double twist process as described below, as shown in FIG.
As shown in FIGS. 3 and 5, the single strand Fs is stretched over the first grooved roller 2a, then the single twist Fs is stretched over the second roller 2b, and then the first and second rollers 2a, 2b. The filament F is sequentially passed around rollers provided coaxially with each other, and finally the filament F is set so as to be connected to the filament supply port 1.

In this case, the diameter D at the bottom of the groove of the first grooved roller 2a depends on the total denier of the filament used, the angle θ between the double-twist Fd part and the single-twist Fs part, etc. It is preferable that the diameter is slightly larger than the diameter of the twisted Fd,
For example, it needs to be 10 to 500 mm, preferably 20 to 300 mm, and most preferably 30 to 150 mm. Furthermore, the depth of the groove needs to be larger than the diameter of the double-twisted Fd to be formed. Fourth
As shown in the figure, the angle θ between the double-twisted Fd part and the single-twisted Fs part is preferably 90° or less, particularly 0 to 85°.
°, most preferably 20 to 70 °. Although productivity increases by increasing the filament drawing speed, it is necessary to increase the heating means and cooling means accordingly. Furthermore, the grooved first roller 2a
The width of the groove is set so that the double strands that are formed will not be further twisted to form triple or more strands or irregularly shaped strands.
It is desirable that the diameter be slightly wider than the diameter of the double twist.
Note that instead of the groove, two plates having the above-mentioned widths may be attached to the grooveless roller perpendicularly to its axis. In addition, when a plurality of rollers are provided coaxially on the first and second rollers 2a and 2b, the grooves of one roller are connected to the grooves of the opposing roller, as shown in FIG. It is desirable to have it between the two. Further, a guide 38 may be provided between the grooves. Since the roller 2 can rotate freely, it rotates depending on the drive of the delivery roller 6, which will be described later.

If the pulling speed is not high enough to sequentially form double twists (slow pulling), triple twists will occur, and if pulling is fast, there will be single twist portions that do not become double twists.

The guide means 3 equipped with a heating means includes a pipe 3a through which the double-twisted filament Fd is passed;
It consists of a jacket 3b outside this pipe 3a, a pipe 3c for introducing high-pressure steam into the jacket 3b, and a pipe 3d for discharging it. It is desirable to drill a large number of holes in the portion of the pipe 3a covered by the jacket 3b. Therefore, it is desirable that the inner diameter of the pipe 3a is slightly larger than the diameter of the double strand, similar to the groove width of the first roller 2a, so that the formed double strand is not further twisted. Further, it is desirable that the distance between the guide means and the first roller 2a be as small as possible so that the double twist is not further twisted. Similarly, it is desirable that the distance between the twisting device 4 and the guide means 3, which will be described later, be as small as possible. In addition to this, the heating means may be electric heating, infrared heating, high frequency heating, or the like. Furthermore, in order to improve efficiency, the heating means may be provided to heat not only the guide means but also the entire single twisting process consisting of the rollers 2a and 2b, as shown in FIG. in this case,
The heating part of the guide means 3 can be made small and optionally omitted.

If a large number of holes are bored in the pipe 3a, the double-twisted filament will come into direct contact with the steam and will be heated. In this case, it is desirable to seal the loss of steam with a sealing member 7 made of an elastic material such as rubber.

As shown in FIGS. 1-2 and 8, the twisting force applying and cooling means 4 includes two rotating disks 8 and 9.
A plurality of arms 10, 11, 12, for example, 3 to 4, are connected between the peripheral edges of the rotating disks 8, 9 by fixing them with nuts 13, 14, etc. Grooved rollers 15, 16, 17 are rotatably inserted into the arms 10, 11, 12,
It is positioned by a collar 18, a flange 19, etc. Filament passage holes 20 and 21 are bored at the rotation centers of the rotary plates 8 and 9. In the filament passage holes 20 and 21, tangle-shaped guides 22 and 23 are fixed to the inner sides of the disks 8 and 9 (on opposing surfaces) for smoothly guiding the passage of the filament. rotating disk 8,
9 is connected to the hollow shaft 24 by a disk 8 fixed to a flange 25 of the hollow shaft 24, and the hollow shaft 24 is supported by bearings 26 and 27. A drive pulley 28 is fixed to the hollow shaft 24, and the pulley 28 connects a belt 29 to a pulley 32 connected to a power source (for example, a motor) 30 and a transmission 31. It goes without saying that sprockets and chains can be used in place of the pulleys 28, 32 and belt 29.

The tension drive roller 6 consists of a plurality of rollers arranged in a zigzag pattern, for example, 4 to 6 delivery roller groups 6a, 6b, 6c, 6d, 6e,
These delivery roller groups 6a to 6e are connected to each delivery roller 6a to 6e via an idle gear 35 from a gear 34 connected to the transmission 33 connected to a power source (not shown). The gears 36a to 36e rotate at the same predetermined rotational speed. In addition, a free roller 37 is provided in front of the delivery roller groups 6a to 6e if necessary.

The filament cutting means 5 is a rotary cutter 5 equipped with a cutting device, as shown in FIGS. 1-2 and 6. This rotary cutter 5
consists of a rotor disk 40 and a rotor ring 41 via a rotor spider 39, this rotor spider 39 is provided with a number of grooves, knives 42 are inserted into the grooves, and are radially set up on the rotor ring 41, knife retainer 4
3, and the knife retainer 43 is fixed to the rotor disk 40 by bolts 44. At the bottom of the rotor ring 41 is a hopper 45.
is provided. The shaft of the rotary cutter is connected to a transmission 47 by a coupling 46 and further connected to a torque motor 48. Further, a presser roller 50 is fitted into a groove 49 formed between the rotor disk 40 and the rotor ring 41. This presser roller 50 is attached to the swing arm 51
The swing arm is attached to the frame 52 by means of a swing arm, and the gap between the swing arm and the cutting edge of the knife 42 is adjusted by swinging the swing arm. swing arm 51
is swung by attaching the handle 53 to the socket 55 and rotating the screw 54, and is pressed toward the knife 42. This allows the untwisted filament to be pulled and cut at the same time.

Note that instead of using a torque motor to rotate the rotary cutter 5, a variable speed motor (ES motor) may be used, and in this case, there is a A step roller (not shown) can be used.

Next, a method for producing a three-dimensional curl filament using the above-mentioned apparatus will be explained.

A plurality of filaments F, for example, synthetic fiber filaments, are pulled out from a plurality of bobbins (not shown), passed through the filament supply port 1, and applied to the first and third rollers 2a and 2b of the single-twist transfer roller group 2.
and as shown in FIG.
6 and 17 in order, and after passing through the tangle-like guide 23, the delivery rollers 6a to 6e are successively passed in a staggered manner, and further connected to the rotary cutter 5.

Next, the power source 30 is driven to rotate the pulley 28. At the same time, another power source (not shown) is driven to operate the transmission 33. Then, the rotary disks 8 and 9 rotate together with the hollow shaft 24, and as a result, a groove is formed between the truss-shaped guide 22 and the grooved roller 15 on which the filament is initially stretched. The filament is twisted by the twisting force caused by the rotation of the roller 15 on the rotating disks 8 and 9, and this twisting force not only reaches the single twist transfer roller group 2, but also applies the twisting force to the filament. Applying a twisting force to the first roller 2a of the transfer roller group 2
Give the filament a double twist Fd up to the first groove of the filament. As a result, the double twist shown in FIG. 9 is given as only a single twist without wavering before that, but the double twist Fd that is formed reaches the first roller 2a. However, Laura 2
A partial twisting force is applied to the filament stretched between a and 2b without affecting the filament, and the filament is twisted into a single twist Fs. The roller 2a has such an effect of preventing the spread of double twist only when the diameter of the roller 2a is within the above range. In other words, if the diameter is less than 10 mm,
Since the diameter is too small for the size of the double twist formed by the total denier of 5000 to 3000000, the pressing force is insufficient.On the other hand, if it exceeds 500mm, the influence of the opposing tension becomes small and the roller This is thought to be because the pressing force applied to 2a is dispersed. Also, the reason why the filament is wound around the rollers 2a and 2b two to four times back and forth is because when the filament F is double-twisted, the length becomes about one-fourth of that without twisting. Rollers 2a, 2b
Resistance is generated between the filament and the roller, and the twisting stress exerts a preventive effect here, preventing the spread of double twisting beyond this point.

The filament with the double twist formed is heated by steam or the like while being guided by the guide means 3 so that the double twist is not further twisted, and further cooled by the cooling means 4 as described later to complete the heat setting. . In this case, the guide means 3 and the roller 2a
It is better that the distance between the two holes is as narrow as possible, and the closer the outlet is to the inlet of the hollow shaft 24, the better. This is because it is difficult for a large denier monofilament aggregate that has been heavily twisted into a double twist to maintain a straight state, which poses a problem in the manufacturing process of three-dimensional curl filaments. Note that this guide means 3 is also desirably a pipe having a diameter slightly larger than the diameter of the double-twisted filament.

The double-twisted filament Fd formed between the roller 2a and the grooved roller 15 is heated by the guide means 3, and then passed between the grooved rollers 15, 16, 17 several times, and then the rotating disk While being air-cooled as the delivery rollers 8 and 9 rotate, it moves between the grooved rollers 15, 16, and 17 due to the tensile force of the delivery rollers 6a to 6e, as will be described later. Reach 23. Meanwhile, the double-twisted filament is air cooled to complete the heat setting. Therefore, the width of the grooves, the number of grooves (the number of threads), the number of rollers, the spacing between the rollers, etc. of the grooved rollers 15, 16, and 17 are such that curls of the twisted thick denier monofilament aggregates do not fit inside the grooves. It is set so that it fits well without sticking out. Therefore, the width of the groove should be slightly larger than the diameter of the double-twisted filament, and the depth should be larger than the diameter. It is desirable that the grooved rollers 15, 16, and 17 rotate freely. Note that the double-twisted filament Fd is connected between the last groove of the grooved roller 17 and the wrapper-like guide 23 after the heat setting is completed.
As a result of the rotation of the grooved roller 17 on the rotating disk 9 about the tangle-shaped guide 23, a twisting force in the opposite direction is applied, and an untwisting phenomenon occurs behind the tangle-shaped guide 23 as a fulcrum.

Next, the untwisted filament is transferred to the transmission 33
The delivery rollers 6a to 6e are pulled by the rotational force of the delivery rollers 6a to 6e, which are rotated at the same circumferential speed by the driving power transmitted from the delivery rollers 6a to 6e. Therefore, the pulling speed of the double twist in this device depends on the circumferential speed of these delivery rollers 6a to 6e, and their rotational speed is set to maintain the required speed.

Next, beyond the delivery rollers 6a to 6e, the untwisted filament is transferred to a torque motor 4.
At the same time, the rotary cutter 5 driven by the rotary cutter 8 is transported using the pressing point of the swing roller 50 as a fulcrum, and at the same time, the knife 42 is cut to a predetermined length, for example, 30 to 300, by the pressing force of the swing roller 50.
The staple fiber is cut into a length of 50 to 150 mm to obtain a three-dimensional curled filament staple fiber as shown in FIG. Note that the torque motor 48
is connected to a power source via a transformer (not shown).

In the above device, the transfer speed of the filament is determined by the degree of twisting force and untwisting, and the rotation of the delivery rollers 6a to 6e rotating at the same circumferential speed is controlled by the transmission 33 by the power transmitted from the transmission 33.
3, the filament tensioning speed changes, and since the untwisted filament has curls, the circumferential speed of the rotary cutter 5 always changes depending on the running (pulling) of the filament. Cutting to size is difficult unless speed is matched. Since the rotary cutter 5 is driven by a torque motor, appropriate tension is always applied to the rotary cutter 5, making it possible to cut to a fixed size. Also, instead of using a torque motor, the ES
A motor may be used, and in this case, a step roller (not shown) may be used between the delivery roller groups 6a to 6e and the rotary cutter 5 to perform the same operation. Therefore, difficulty in untwisting due to loosening between the supports, curling due to too strong tension, and overloading of the motor, which tend to occur when using a normal motor, are eliminated.

Example 1 A polyester filament having a total denier of 500,000 denier of 30 denier was used as a monofilament, and grooved rotary free rollers 2a and 2b with a diameter of 80 mm at the groove bottom were used so that the angle θ between the double-twisted part and the single-twisted part was The apparatus was installed at an angle of 45 degrees and spanned as shown in Figure 3, and the apparatus shown in Figures 1 and 2 was operated with the rotating plates 8 and 9 rotating at 120 rpm. When heat setting was performed and the filament was operated at a filament transfer speed of 2.5 m/min in the untwisting section, no spread of double twist was observed at the roller 2a section, 64 ridges were formed per 1 m, and the total length was approximately 1/2.
It was reduced to 3. Further, when the untwisted filament was cut into a length of 80 mm using the rotary cutter 5 driven by the 30 Kg/cm ² torque motor 48, cutting to size was performed.

Example 2 The same method as in Example 1 was carried out except that the rotational speed of the rotating disks 8 and 9 was set to 148 rpm and the transport speed of the untwisted filament was set to 2.9 m/min. Similar results were obtained with continuous twisting.

[Brief explanation of the drawing]

1 is a perspective view of the device according to the invention, FIG. 2 is a sectional view of the device according to the invention, FIG. 3 is an enlarged perspective view of the single twisting means, and FIG. 4 is a sectional view taken along the - line in FIG. 3. , Figure 5 is a sectional view taken along the - line in Figure 3, Figure 6 is a sectional view of the rotary cutter, and Figure 7 is a sectional view of the rotary cutter.
8 is an enlarged side view including a partial cross section of the rotating part, FIG. 9 is a perspective view of a filament with double twist, and FIG. FIG. 10 is a perspective view of a three-dimensional curl filament. 1...Filament supply port, 2, 2a, 2b...
...single twist transfer roller, 3, 3a...guiding means,
4... Twisting force applying and cooling means, 5... Filament cutting means, 6... Tension drive roller, 8, 9
... Rotating plate, 10, 11, 12 ... Shaft, 1
5, 16, 17...Grooved roller, 21...Filament passage hole, 22, 23...Rump shaped guide, 24...Hollow shaft, 26, 27...Bearing, 6a-6e...Delivery roller, 36a-
36e...Gear, 40...Rotary disk,
41...Rotary ring, 42...Knife, 4
5...Hopper, 50...Lola.

Claims (1)

[Claims] 1. A plurality of thick denier filaments with a total denier of 5000 are placed between a grooved first free roller having a diameter of 10 to 500 mm at the groove bottom and at least one other second free roller. A single twisting process in which the filament is stretched with ~3,000,000 denier and then a single twist is formed in the filament by applying twisting force in the double twisting process, and a double twist is formed in the filament from the starting point after passing through the single twisting process. A double-twisting step in which the double-twisted filament is heated by passing it through a cylindrical guide means, and the formed double-twisted filament is cooled while applying a twisting force to give the filament a double twist. a cooling process to complete the heat setting;
An untwisting process in which the heat-set double-twisted filament is pulled and untwisted by a tension drive roller to form a three-dimensional curl filament, and a cutting process to cut the untwisted three-dimensional curl filament. A method for producing a three-dimensional curl filament. 2. The cooling process for applying the twisting force and completing the heat setting is performed using a plurality of rotatable plates rotatably mounted between two rotary plates with a filament passage hole bored in the center of rotation. The rotation of the rotating member consisting of the grooved rollers causes the filament stretched between the second free roller and the filament passage hole on the roller side of the rotating plate to rotate on the rotating plate. 2. The method according to claim 1, wherein the double-twisted filament formed by applying a twisting force is stretched between the grooved rollers and air-cooled by the rotation of the rotating member. 3. The method according to claim 1, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 90° C. or less. 4. The method according to claim 1, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 0 to 85 degrees. 5 Filament is 20~ as monofilament
5. A method according to any one of claims 1 to 4, wherein the denier is 3000 denier. 6. The method according to any one of claims 1 to 5, wherein the cutting step is performed by a rotary cutter driven by a torque motor. 7 a means for cutting the untwisted filament; a plurality of tension drive rollers arranged in series for tensioning and untwisting the cooled double-twisted filament; A twisting force is applied to a filament comprising a plurality of grooved rollers rotatably pivoted between two rotary plates having a filament passage hole bored in the center of rotation near the periphery. means for cooling the formed double-twisted filament; cylindrical guiding means for the double-twisted filament provided in front of the roller group; and heating means for the formed double-twisted filament. , provided in front of the guide means and having a diameter of 10 to 500 at the bottom of the groove.
A grooved first free roller having a diameter of mm and at least one other second free roller prevent the double twist from spreading to the filament at a certain point due to the twisting force in the double twisting process. A three-dimensional curl filament manufacturing device comprising a single twisting means for forming a single twist. 8. Claim 7, wherein the filament passage holes formed at the rotation centers of the two rotary plates are each provided with a rattle-shaped guide on each opposing side.
Equipment described in Section. 9. The device according to claim 7, wherein the grooved roller is rotatably inserted through an arm connected between two rotary plates. 10. The device according to claim 7, wherein the tension drive roller comprises a plurality of rollers arranged in series in a staggered manner and rotating at the same circumferential speed. 11. The apparatus according to claim 7, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 90 degrees or less. 12. The apparatus according to claim 7, wherein the first and second rollers are arranged such that the angle between the double twist and the single twist to be formed is 0 to 85 degrees. 13. The device according to any one of claims 7 to 12, wherein the first roller has a diameter of 20 to 300 mm. 14 Filament as monofilament20
14. A device according to any one of claims 7 to 13 having a denier of ~3000 denier. 15 Claim 7, wherein the cutting device is a rotary cutter driven by a torque motor.
Apparatus according to any one of clauses 1 to 14. 16 The filament has a total denier of 5000~
Claims 7 to 1 which are 3,000,000
Apparatus according to any one of clause 5.