JPS6252057B2 - - 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. An apparatus for continuously producing synthetic fiber crimped staples for cushion materials has been proposed. (Jitko Showa 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-slip 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 heating means for applying a required rotational tension to form a single twist and guiding the filament; We have discovered a device consisting of double twist spread stopping means provided on the last roller of a roller group (Japanese Patent Application Laid-open No. 144448/1983). However, the above-mentioned equipment can only produce within a narrow total denier range, and it is difficult to adjust the double twist processing and transfer speed to the total denier, making processing operations complicated and work efficiency low. It had the disadvantage of being 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 apparatus for forming three-dimensional curl filaments in a wide range of total deniers, and separating double twist processing and adjustment of transfer speed 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 first free roller with a groove 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 method for manufacturing a three-dimensional curl filament, which includes a cooling process to complete the heat setting, and an untwisting and cutting process to cut the three-dimensional curl filament while untwisting the heat-set double-twist filament. achieved.

The method includes means for applying an untwisting force to tension and untwist the cooled double-twisted filament and for cutting the untwisted filament, and a means for applying an untwisting force to pull and untwist the cooled double-twisted filament and for cutting the untwisted filament, and a filament disposed in front of the cutting means and at a center of rotation. A twisting force is applied to a filament comprising a plurality of grooved rollers rotatably pivoted between two rotary plates with passage holes near their peripheries. means for cooling the twisted filament; a cylindrical guiding means for the double-twisted filament provided in front of the roller group; a heating means for the double-twisted filament being formed; A grooved free roller provided in the front and having a diameter of 10 to 500 mm at the bottom of the groove and at least one other free roller are provided, and the filament is double twisted at a constant level by the twisting force in the double twisting step. This is achieved by a three-dimensional curl filament production apparatus comprising a single twist means that forms a single twist while preventing spread.

The filament used in the present invention includes synthetic fibers and natural fibers such as polyester, polyamide, polypropylene, polyacrylonitrile, polyvinylidene chloride, vinylon, etc. Synthetic fibers are preferred, and polyester fibers are particularly preferred. . In other words, polyester filament has better rigidity and greater repulsion than other synthetic fibers, and as will be described later, when used in the form of a locking material for a cushioning 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 heating means-equipped guide means 3, a twisting force applying and cooling means 4, and a filament untwisting and cutting means 5 are arranged in the order of the filament feeding direction. It is arranged. 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, in the filament F, the double twist Fd formed in the double twist process is
As shown in FIGS.
Fs is stretched around the second roller 2b, and then sequentially around the rollers provided coaxially with the first and second rollers 2a and 2b, and finally the filament F is connected to the filament supply port 1. It is set to

In this case, the diameter D at the groove bottom of the grooved first 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. The diameter is preferably slightly larger than the diameter, for example, 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, especially 0 to 85°.
°, most preferably 20-70°. 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 second 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. roller 2
Since it 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 (if the tension is slow), triple twists will occur, and if the tension is fast, there will be parts that are single twists but not 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.

The twisting force applying and cooling means 4 consists of two rotating disks 8 and 9, as shown in FIGS. 1 and 2 and FIG.
For example, three to four arms 10, 11, 12 are fixed with nuts 13, 14, etc. and connected by the arms, and grooved rollers 15, 16, 17 are rotatable on the arms 10, 11, 12. It is inserted freely and positioned by the collar 18, 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 discs 8, 9
is connected to the hollow shaft 24 by a disc 8 fixed to a flange 25 of the hollow shaft 24, and the hollow shaft 24 is supported by bearings 26, 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 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 large number of grooves, and knives 42 are inserted into the grooves, radially erected on the rotor ring 41, and fixed by a knife retainer 43, which is fixed to the rotor disk 40 by bolts 44. be done. 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 transmission 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,
Attach the handle 53 to the socket 55 and tighten the screw 54.
The knife 42 is swung by rotating the knife 42.
Pressed to the side. This allows the untwisted filament to be pulled and cut at the same time.

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 flap-like guide 23, it is 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, as shown in FIG. 9, the double twist does not spread beyond that point and becomes only a single twist, but when the formed double twist Fd reaches the first roller 2a, Yes, 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 stretched several times between the grooved rollers 15, 16, 17, and rotated in a rotating circle. As the plates 8 and 9 rotate, the grooved rollers 15, 16, and 17 move between the grooved rollers 15, 16, and 17 due to the tensile force of the rotary cutter 5, as will be described later.
From the last groove of No. 7, a truss-like guide 23 is reached.
Meanwhile, the double-twisted filament is air cooled to complete the heat setting. However, this grooved roller 1
The width of the grooves 5, 16, and 17, the number of grooves (the number of threads), the number of rollers, the spacing between the rollers, etc. are such that the curl of the twisted thick denier monofilament aggregate does not protrude from the groove and is well contained. It is set as follows. 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 after the heat setting is completed between the last groove of the grooved roller 17 and the wrapper-like guide 23 is as follows.
As the grooved roller 17 rotates 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 6b, and the rotational speed thereof is set so as 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 this manner, the rotary cutter used in the present invention serves as one fulcrum for untwisting the double twist, and thus acts as a cutting means while applying the tension necessary for untwisting to the filament. On the other hand, in the above device, not only does the pulling speed of the filament change depending on the degree of twisting, but also the untwisted filament has curls, so unless it is constantly pulled with an appropriate tension, the filament cannot be sized to a fixed size. Cutting is difficult. Since the rotary cutter is driven by a variable speed motor, appropriate tension is always applied to the filament, making it possible to cut the filament to a fixed size. 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 of 300 denier was used as a monofilament, and the total denier was 500,000 denier. Grooved rotary free rollers 2a and 2b with a diameter of 80 mm at the groove bottom were arranged so that the angle θ between the double strand part and the single strand part was 500,000 denier. 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 part, no spread of double twist was observed in the roller 2a part, 64 ridges were formed per 1 m, and the total length was approximately
It has shrunk to 1/3. Also 30Kg/ ^cm2 torque motor 48
When the untwisted filament was cut into a length of 80 mm using a rotary cutter 5 driven by a rotary cutter 5, cutting to a fixed 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, 8, 9... Rotating plate, 10, 1
1, 12... Shaft, 15, 16, 17... Grooved roller, 21... Filament passage hole, 2
2, 23... Lump-shaped guide, 24... Hollow shaft, 26, 27... Bearing, 40... Rotary disk, 41... Rotary ring, 42...
Knife, 45...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;
A method for producing a three-dimensional curl filament comprising an untwisting and cutting step for cutting the three-dimensional curl filament while untwisting the double-twist filament heat-set in this manner. 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 degrees 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 variable speed motor. 7 A means for applying an untwisting force to pull and untwist the cooled double-twisted filament and for cutting the untwisted filament, and a filament passage hole provided in front of the cutting means and provided at the center of rotation. A twisting force is applied to a filament comprising a plurality of grooved rollers rotatably pivoted between two perforated rotary plates near the periphery, and a double-twisted filament is formed. a means for cooling, a cylindrical guide means for the double-twisted filament provided in front of the roller group, a heating means for the double-twisted filament to be formed, and a means provided in front of the guide means. A first free roller with a groove and a diameter of 10 to 500 mm at the bottom of the groove, and at least one second free roller, the filament is double-twisted by the twisting force in the double-twisting step. A device for producing a three-dimensional curl filament comprising a single twisting means that forms a single twist while stopping the spread at a certain point. 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 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 90 degrees or less. 11. 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. 12. The device according to any one of claims 7 to 11, wherein the first roller has a diameter of 20 to 300 mm. 13 Filament is 50 as monofilament
13. A device according to any one of claims 7 to 12 having a denier of ~3000 denier. 14. The device according to any one of claims 7 to 13, wherein the filament untwisting and cutting means comprises a rotary cutter driven by a variable speed motor. 15 The filament has a total denier of 5000
13. The device according to any one of claims 7 to 12, wherein the amount is .about.3,000,000.