US20060145385A1 - Device and method for manufacturing thread line - Google Patents

Device and method for manufacturing thread line Download PDF

Info

Publication number
US20060145385A1
US20060145385A1 US10/516,835 US51683504A US2006145385A1 US 20060145385 A1 US20060145385 A1 US 20060145385A1 US 51683504 A US51683504 A US 51683504A US 2006145385 A1 US2006145385 A1 US 2006145385A1
Authority
US
United States
Prior art keywords
filaments
numerous
numerous filaments
yarn
spinning
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.)
Abandoned
Application number
US10/516,835
Other languages
English (en)
Inventor
Takashi Fujii
Takao Sano
Hiroki Furuta
Masahito Hisada
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Industries Inc
Original Assignee
Toray Industries Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Toray Industries Inc filed Critical Toray Industries Inc
Assigned to TORAY INDUSTRIES, INC. reassignment TORAY INDUSTRIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HISADA, MASAHITO, FURUTA, HIROKI, FUJII, TAKASHI, SANO, TAKAO
Publication of US20060145385A1 publication Critical patent/US20060145385A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • 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
    • D01D5/088—Cooling filaments, threads or the like, leaving the spinnerettes
    • D01D5/092—Cooling filaments, threads or the like, leaving the spinnerettes in shafts or chimneys
    • 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
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)

Definitions

  • the present invention relates to a method and apparatus for producing a yarn consisting of numerous filaments, comprising the steps of discharging a flowable polymer from numerous spinning holes formed in a spinneret, to form the numerous filaments, letting the formed numerous filaments pass through a filament passage satisfying specific gas stream conditions of a spinning tube installed below the spinneret, taking up the numerous filaments coming out of the filament passage, and winding the numerous filaments.
  • a typical example of the polymer used in the yarn production method is a polyester polymer (e.g., polyethylene terephthalate). Furthermore, the yarn production method can also be preferably used for producing a partially oriented yarn.
  • a spinneret 1 For producing a yarn, especially a partially oriented yarn (POY) of a polyester or the like, generally an apparatus shown in FIG. 1 is used.
  • a spinneret 1 has numerous spinning holes 6 .
  • Numerous filaments F discharged from the spinning holes 6 are cooled and solidified by means of cooling air 3 a supplied by a cooling means 3 .
  • the solidified numerous filaments F are taken up by a godet roller 4 , to form a yarn Y.
  • the yarn Y consisting of the numerous filaments F is wound around a bobbin by a winder 5 , to produce a yarn package.
  • the take-up speed is increased to 4,000 m/min, the elongation of the yarn becomes 90%, and if the take-up speed is increased to 5,000 m/min, the elongation of the yarn becomes 65%. At a higher take-up speed, the elongation of the produced yarn becomes lower.
  • a circular spinneret 1 shown in FIG. 2 is used.
  • the spinneret 1 has numerous spinning holes 6 .
  • the polymer discharged from the numerous spinning holes 6 forms numerous filaments F.
  • the numerous filaments F run downward.
  • cooling air 3 a is supplied from one side only. Especially when the take-up speed is high, the volume of the cooling air 3 a is also increased. Therefore, the filaments F swing very greatly.
  • the respective filaments F are cooled in different conditions.
  • the yarn Y consisting of the numerous filaments F produced in this way has filament irregularity.
  • FIG. 3 An attempt to overcome the difficulty for obtaining a high elongation yarn at a high speed is described in U.S. Pat. No. 5,824,248. The outline of the attempt is shown in FIG. 3 .
  • the spinning apparatus shown in FIG. 3 has a cylindrical cooling means 55 and a tube 73 having a diameter smaller than that of the cylindrical cooling means 55 below a spinneret 1 . Cooling air 55 a of the cylindrical cooling means 55 generates a descending air stream in the tube 73 positioned downstream of it. It is proposed to impart an air stream in the tube 73 to the numerous filaments F discharged from the numerous spinning holes 6 of the spinneret 1 .
  • JP-A-08-506393 proposes to adjust a flow velocity of an air stream flowing in a tube to a velocity equal to a running speed of the polymer, for decreasing a take-up tension T acting on the filaments. It is described that this constitution allows a yarn to be produced stably even if a take-up speed of the yarn is kept high.
  • JP-A-2001-262427 proposes to inject a heating fluid from heating fluid injection holes formed around the spinning holes of the spinneret obliquely downward to the running filaments. It is intended that the filaments discharged from the spinning holes are kept at a high temperature and made thinner by means of the heating fluid flow. It is described that with this constitution, even if the spinning speed is raised, that is, even if the filament take-up speed is raised, a high elongation yarn can be obtained. Furthermore, it is described that if a suction means is installed downstream of the heating fluid injection holes, the discharged filaments can be made thinner more positively.
  • the heating fluid injected from the heating fluid injection holes flows toward the suction means. So, there is a problem that the heating medium heats the suction means. Furthermore, there is another problem that the heating fluid introduced into the suction means destabilizes temperature of a gas stream running in the suction means. The unstable temperature condition affects the filaments running in the suction means. The yarn produced after undergoing this condition has filament irregularity.
  • the heating fluid injection holes are formed directly in the spinneret, the injected heating fluid does not have an established passage on the discharge face of the spinning holes of the spinneret, and is merely released into the space between the spinneret and the suction means. For this reason, between the central portion and the end portions of the numerous spinning holes arranged along straight lines, a problem arises that force of the heating fluid acting on the filaments becomes different.
  • the yarn consisting of numerous filaments produced like this has filament irregularity.
  • a gas is generated from the polymer flow as just discharged from the spinning holes of the spinneret.
  • the gas contains low polymerization products of the intended polymer, i.e., the monomer, oligomer (hereinafter called a volatile substance), etc.
  • the volatile substance is deposited on the spinneret face and its vicinity. The deposit causes the filaments to be broken during spinning. If a filament is broken, the spinning work must be suspended to correct the trouble, disturbing the continuous operation of spinning process.
  • Such a gas is generated not only in the case where polyethylene terephthalate is spun, but also in the case where another polymer is spun.
  • thermally decomposable polymers such as polyamides, polypropylene and aliphatic polyesters (polylactic acid, etc.) generate the gas in a large amount.
  • the deposition of the volatile substance caused by the generated gas disturbs the continuous operation of spinning process.
  • JP-B-50-13924 and JP-A-9-250022 respectively disclose a device for sucking a gas generated below the spinneret.
  • the device sucks the gas from lateral sides of the polymer flow (filaments F) as just discharged the spinning holes of the spinneret.
  • the object of the invention is to overcome the above-mentioned problems of the prior art, by providing a method and apparatus for producing a yarn free from irregularity and having a high elongation even if the speed for taking up the numerous filaments is raised.
  • the present invention provides a method for producing a yarn consisting of numerous filaments, using:
  • gas injection holes are provided, which inject gas obliquely downward from outside the numerous filaments entering the filament passage of the spinning tube, toward the numerous filaments, while the numerous filaments are still flowable, to ensure that the numerous filaments can be disposed along one straight line or one circle without overlapping each other, and further to ensure that, subsequently after disposing the numerous filaments, the injected gas can form a gas stream flowing downward together with the numerous filaments in the filament passage of the spinning tube, and
  • the velocity of the gas stream flowing downward together with the numerous filaments in the filament passage of the spinning tube is not less than 60% of the take-up speed of the numerous filaments taken up by the filament take-up means.
  • a gas suction device is installed between the spinneret and the spinning tube, to suck the gas existing around the numerous filaments and to discharge the gas outside.
  • the numerous filaments are disposed along one straight line, that the cross sectional form of the filament passage of the spinning tube is rectangular, that the direction of the long sides of the rectangle agrees with the direction of the straight line, and that the following relation is satisfied: d ⁇ 3 ⁇ Ex ⁇ d ⁇ 20 where Ex is the length of the short sides of the rectangle, and d is the diameter of the spinning holes.
  • the numerous spinning holes are arranged in straight lines, and that the number of the straight lines is 3 or less.
  • La La ⁇ Lg/ 2 where Lg is the distance between the spinneret and the position at which the numerous filaments are solidified to lose their flowability and reach the take-up speed of the numerous filaments taken up by the filament take-up means, and La is the distance between the spinneret and the position at which the acceleration of the numerous filaments becomes largest.
  • a velocity of the gas stream flowing downward together with the numerous filaments in the filament passage of the spinning tube is higher than the running speed of the numerous filaments in the range of the distance Lg between the spinneret and the position at which the running speed of the numerous filaments reaches the take-up speed of the numerous filaments taken up by the filament take-up means.
  • a gas suction and discharge means for sucking and discharging gas existing around the numerous filaments running from the spinning holes toward the filament passage is installed between the spinneret and the spinning tube, to ensure that the gas existing around the numerous filaments can be sucked and discharged.
  • the numerous filaments are disposed along one straight line, that the cross sectional form of the filament passage of the spinning tube is rectangular, that the direction of the long sides of the rectangle agrees with the direction of the straight line, and that the following relation is satisfied Ex ⁇ 10 mm where Ex is the length of the short sides of the rectangle.
  • the apparatus for producing a yarn of the invention is as follows.
  • An apparatus for producing a yarn consisting of numerous filaments having:
  • gas injection holes are provided, which inject gas obliquely downward from outside the numerous filaments entering the filament passage of the spinning tube, toward the numerous filaments, while the numerous filaments are still flowable, to ensure that the numerous filaments can be disposed along one straight line or one circle without overlapping each other, and further to ensure that, subsequently after disposing the numerous filaments, the injected gas can form an air stream flowing downward together with the numerous filaments in the filament passage of the spinning tube, and
  • a means is provided for adjusting the injection conditions of the gas injected from the gas injection holes or adjusting the take-up speed of the numerous filaments taken up by the filament take-up means, to ensure that the velocity of the gas stream flowing downward together with the numerous filaments in the filament passage of the spinning tube is not less than 60% of the take-up speed of the numerous filaments taken up by the filament take-up means.
  • a gas suction device is installed between the spinneret and the spinning tube, to suck the gas existing around the numerous filaments and to discharge the gas outside.
  • the numerous filaments are disposed along one straight line, that the cross sectional form of the filament passage of the spinning tube is rectangular, that the direction of the long sides of the rectangle agrees with the direction of the straight line, and that the following relation is satisfied: d ⁇ 3 ⁇ Ex ⁇ d ⁇ 20 where Ex is the length of the short sides of the rectangle, and d is the diameter of the spinning holes.
  • the numerous spinning holes are arranged in straight lines, and that the number of the straight lines is 3 or less.
  • La La ⁇ Lg/ 2 where Lg is the distance between the spinneret and the position at which the numerous filaments are solidified to lose their flowability and reach the take-up speed of the numerous filaments taken up by the filament take-up means, and La is the distance between the spinneret and the position at which the acceleration of the numerous filaments becomes largest.
  • the velocity of the gas stream flowing downward together with the numerous filaments in the filament passage of the spinning tube is higher than the running speed of the numerous filaments in the range of the distance Lg between the spinneret and the position at which the running speed of the numerous filaments reaches the take-up speed of the numerous filaments taken up by the filament take-up means.
  • a gas suction and discharge means for sucking and discharging gas existing around the numerous filaments running from the spinning holes toward the filament passage is installed between the spinneret and the spinning tube, to ensure that the gas existing around the numerous filaments can be sucked and discharged.
  • the numerous filaments are disposed along one straight line, that the cross sectional form of the filament passage of the spinning tube is rectangular, that the direction of the long sides of the rectangle agrees with the direction of the straight line, and that the following relation is satisfied: Ex ⁇ 10 mm where Ex is the length of the short sides of the rectangle.
  • FIG. 1 is a schematic typical view showing a conventional yarn production apparatus.
  • FIG. 2 is a schematic typical view showing the bottom face of the spinneret used in the apparatus of FIG. 1 .
  • FIG. 3 is a schematic typical view showing another conventional yarn production apparatus than the apparatus of FIG. 1 .
  • FIG. 4 is a schematic typical view showing an embodiment of the yarn production apparatus of the invention.
  • FIGS. 5A, 5B and 5 D are schematic typical views showing the bottom faces of three typical examples of the spinneret used in the apparatus of FIG. 4 .
  • FIG. 5C is a projected typical front view showing the spinneret of FIG. 5B .
  • FIG. 5E is a projected typical front view of the spinneret of FIG. 5D .
  • FIG. 6 is a schematic vertical sectional view showing the spinning tube used in the apparatus of FIG. 4 .
  • FIG. 7 is a schematic X-X cross-sectional view showing the spinning tube of FIG. 6 .
  • FIG. 8 is a schematic perspective view showing a partial upper portion of the spinning tube of FIG. 4 .
  • FIG. 9 is a schematic vertical sectional view showing another mode of the spinning tube of FIG. 4 .
  • FIG. 10 is a schematic vertical sectional view showing a lower portion of a further other mode of the spinning tube of FIG. 4 .
  • FIG. 11 is a partial schematic vertical sectional view showing a mode in which a discharge-destined flow suction means is provided below the spinning tube in the apparatus of FIG. 4 .
  • FIG. 12 is a partial schematic vertical sectional view showing a mode in which flow regulation sections are installed above the spinning tube in the apparatus of FIG. 4 .
  • FIG. 13 is a perspective view showing an example of the grate members installed in the flow regulation sections of FIG. 12 .
  • FIG. 14 is a partial schematic perspective view showing a mode in which an air stream regulation means is installed above the spinning tube in the apparatus of FIG. 4 .
  • FIG. 15 is a schematic perspective view showing a temperature regulation means installed above the spinning tube in the apparatus of FIG. 4 .
  • FIG. 16 is a schematic perspective view showing another mode of the temperature regulation means of FIG. 15 .
  • FIG. 17 is a partial schematic vertical sectional view showing a mode in which a compressed air circulation passage is added to the spinning tube in the apparatus of FIG. 4 .
  • FIG. 18 is a schematic typical view showing another embodiment of the yarn production apparatus of the invention.
  • FIG. 19 is a schematic vertical sectional view showing a mode of the gas suction device used in the apparatus of FIG. 18 .
  • FIG. 20 is a schematic vertical sectional view showing another mode of the gas suction device used in the apparatus of FIG. 18 .
  • FIG. 21 is a schematic vertical sectional view showing a further other mode of the gas suction device used in the apparatus of FIG. 18 .
  • FIG. 22 is a schematic cross sectional view showing the gas suction device used in the apparatus of FIG. 18 .
  • FIG. 23 is a schematic typical view showing a further other embodiment of the yarn production apparatus of the invention.
  • FIG. 24 is a schematic perspective view showing a mode of the grate members of the flow regulation sections of FIG. 23 .
  • FIG. 25 is a schematic perspective view showing the flow regulation sections of FIG. 23 .
  • FIG. 26 is a schematic typical view showing a further other embodiment of the yarn production apparatus of the invention.
  • FIG. 27 is a graph showing how the speed of the filaments composed of a polymer discharged from the spinneret changes in relation with the distance from the spinneret in the apparatus of FIG. 4 .
  • FIG. 28 is a schematic perspective view showing the spinning tube and the oiling means installed in the apparatus of FIG. 4 .
  • FIG. 29 is a schematic perspective typical view showing a further other embodiment of the yarn production apparatus of the invention.
  • FIG. 30 is a partial schematic perspective typical view showing a further other embodiment of the yarn production apparatus of the invention.
  • FIG. 31 is a partial schematic perspective typical view showing a further other embodiment of the yarn production apparatus of the invention.
  • FIG. 32 is a schematic typical view for illustrating the method of measuring the running speed of filaments.
  • FIG. 33 is a graph showing how the speed of the filaments composed of a polymer discharged from the spinneret changed in relation with the distance from the spinneret in Examples 1 through 4.
  • FIG. 34 is a graph showing how the speed of the filaments composed of a polymer discharged from the spinneret changed in relation with the distance from the spinneret in Comparative Examples 1 through 3.
  • FIG. 35 is a graph showing how the speed of the filaments composed of a polymer discharged from the spinneret changed in relation with the distance from the spinneret in Examples 1 and 5 and Comparative Example 4.
  • a yarn production apparatus 10 of the invention has a spinneret 12 engaged with a spinning block 11 in a melt-spinning machine (not illustrated) and having numerous spinning holes 13 formed for continuously discharging a flowable polymer for forming filaments.
  • a spinning tube (ejector) (air applying means) 20 is installed below the spinneret 12 and being spaced from the spinneret 12 .
  • the spinning tube 20 has a filament passage 25 ( FIG. 6 ) through which the numerous filaments F formed by the numerous spinning holes 13 and running downward from the spinneret 12 pass.
  • an oiling means 17 is installed for applying an oiling agent to the numerous filaments F coming from the filament passage 25 of the spinning tube 20 .
  • a first godet roller 14 and a second godet roller 15 constituting a filament take-up means are installed for taking up the numerous filaments F coming from the oiling means 17 .
  • a winding means 16 is installed for winding the numerous filaments F coming from the filament take-up means. The numerous filaments F are wound around a bobbin 16 a as a yarn Y by the winding means 16 , to form a yarn package 16 b.
  • the spinning tube 20 can be moved vertically by means of an elevator 26 installed outside.
  • the elevator 26 comprises a vertically extending and rotatable column 26 d provided with a ball screw 26 b , a motor 26 c for rotating the column 26 d , and a spinning tube support arm 26 a connected at one end with the ball screw 26 b , to be able to move vertically along the column 26 d with the rotation of the ball screw 26 b , and connected at the other end with the spinning tube 20 .
  • the elevator 26 is actuated to adjust the distance between the bottom face of the spinneret 12 and the top face of the spinning tube 20 to a desired value.
  • FIG. 5A is a bottom face view showing an example of the spinneret 12 used in the apparatus of FIG. 4 .
  • the spinneret 12 A of FIG. 5A has numerous spinning holes 13 having a hole diameter of d (mm).
  • the numerous spinning holes 13 are arranged along a straight line Z at a pitch of P (mm).
  • Six spinning holes 13 are shown in FIG. 5A .
  • the distance between the center of the rightmost spinning hole 13 and the center of the leftmost spinning hole 13 is indicated by symbol dw.
  • FIG. 5B is a bottom face view showing another example of the spinneret 12 used in the apparatus of FIG. 4 .
  • the spinneret 12 B of FIG. 5B has the spinning holes 13 of the spinneret 12 A of FIG. 5A in two rows, instead of one row.
  • the spinnerets 13 are arranged along straight lines Z 1 and Z 2 parallel to each other. The positions of the spinning holes 13 on the straight line Z 1 and the positions of the spinning holes 13 on the straight line Z 2 are shifted from each other in the straight-line direction. This state is shown in FIG. 5C as projected on the plane including the straight-line direction and the direction of the vertical line to the spinneret 12 B.
  • FIG. 5B the centers of the respective spinning holes 13 are positioned on the straight lines Z 1 and Z 2 respectively, and the distance between the arrangement of the spinning holes 13 on the straight line Z 1 and the arrangement of the spinning holes 13 on the straight line Z 2 is the distance in the direction perpendicular to the straight lines Z 1 and Z 2 , and this distance is indicated by symbol W in FIG. 5B .
  • This distance W is the longest distance between the arrangement lines of spinnerets, that is, in the case where the spinning holes are arranged in 3 rows, the outermost two straight lines are selected for referring to the distance W.
  • FIG. 5D is a bottom face view showing a further other example of the spinneret 12 used in the apparatus of FIG. 4 .
  • the spinning holes 13 are not arranged regularly like straight lines on the surface of the spinneret.
  • the spinning holes 13 are arranged at random.
  • This state is shown in FIG. 5E as projected on the plane including the straight-line direction and the direction of the vertical line to the spinneret 12 D. This state is necessary to ensure that the numerous filaments F are disposed along one straight line without overlapping each other in the case where air is injected obliquely downward from outside the numerous filaments F toward the numerous filaments in the spinning tube 20 described later.
  • FIG. 5E is a bottom face view showing a further other example of the spinneret 12 used in the apparatus of FIG. 4 .
  • the spinning holes 13 are not arranged regularly like straight lines on the surface of the spinneret.
  • the spinning holes 13 are arranged at random.
  • FIG. 5E This state is necessary to ensure that the numerous filaments F
  • the distance between the centers of the spinning holes 13 of the outermost positions in the width direction (the direction perpendicular to the longitudinal direction) of the spinneret 12 D is indicated by symbol W.
  • W the distance between the centers of the spinning holes 13 of the outermost positions in the width direction (the direction perpendicular to the longitudinal direction) of the spinneret 12 D.
  • W the distance between the centers of the spinning holes 13 of the outermost positions in the width direction (the direction perpendicular to the longitudinal direction) of the spinneret 12 D.
  • the numerous spinning holes 13 in the spinneret 12 can also be arranged like a circle, though such an arrangement is not illustrated in the drawings FIGS. 5A-5E .
  • the length of the spinning tube 20 in the straight-line Z direction can be shortened, and the flow rate Ef of the air injected into the spinning tube 20 can be decreased, to allow the reduction of operation cost.
  • the distance W between the respective rows is too large, the discharged filaments F composed of a polymer may be bent greatly, to make the produced yarn irregular. It is preferred to keep the distance W between the respective rows as small as possible, considering the phenomenon that the filaments F are swollen at a position immediately below the spinning holes 13 .
  • the structure of the spinning tube 20 used in the apparatus of FIG. 4 is explained below in reference to FIG. 6 .
  • the spinning tube 20 comprises an air inlet section 22 , an air injection section 23 , a steady flow section 21 and an air discharge section 24 in this order from the upstream side toward the downstream side.
  • the spinning tube 20 has a filament passage 25 through which the numerous filaments F discharged from the spinning holes 13 of the spinneret 12 run toward the filament take-up means 14 , in the range from the air inlet section 22 to the air discharge section 24 .
  • the air injection section 23 has air injection holes 23 a in the wall faces of the filament passage 25 on both sides for injecting air obliquely downward from outside the running numerous filaments F toward the numerous filaments F.
  • the air injection holes 23 a are connected with an air supply device 41 , and compressed air 41 a is supplied to the air injection holes 23 a .
  • the supplied compressed air 41 a is injected into the filament passage 25 from the air injection holes 23 a .
  • the injection causes outside air to be sucked from the top opening of the spinning tube 20 into the air inlet section 22 in the filament passage 25 , to form a suction air flow.
  • the sucked air and the air injected from the air injection holes 23 a flow toward the downstream side in the filament passage 25 and become an airstream with a constant velocity in the steady flow section 21 .
  • the air stream that has passed through the steady flow section 21 is discharged outside from the air discharge section 24 .
  • the air flow injected from the air injection holes 23 a causes the numerous filaments F entering the filament passage 25 to be disposed in a straight line without overlapping each other in the direction perpendicular to the paper surface in FIG. 6 , and the filaments as disposed like this run toward the oiling means 17 .
  • FIG. 7 The X-X sectional view of the spinning tube 20 shown in FIG. 6 is shown in FIG. 7 .
  • the cross sectional form of the filament passage 25 is rectangular. The rectangular form is kept in the range from the inlet of the filament passage 25 in the air inlet section 22 to the outlet of the filament passage 25 in the air discharge section 24 .
  • the direction of the long sides 21 L of the rectangle agrees with the direction in which the spinning holes 13 of the spinneret 12 are arranged side by side. Therefore, the direction of the short sides 21 S of the rectangle is perpendicular to the direction in which the spinning holes 13 of the spinneret 12 are arranged side by side.
  • the length Ey of the long sides 21 L of the rectangle as the cross sectional form of the filament passage 25 is only required to be larger than the distance dw (mm) between the outermost spinning holes 13 of the spinneret 12 A, 12 B or 12 D shown in FIG. 5A, 5B or 5 D.
  • the sizes of the respective rectangles may be different, and in this case, it is only required that the smallest length of the long sides 21 L, 22 L, 23 L and 24 L of the rectangles is larger than the distance dw between the outermost spinning holes.
  • the sizes of the respective rectangles are equal among the air inlet section 22 , the air injection section 23 , the steady flow section 21 and the air discharge section 24 .
  • the respective short sides 21 S, 22 S, 23 S and 24 S of the air inlet section 22 , the air injection section 23 , the steady flow section 21 and the air discharge section 24 satisfy the following relation:
  • the air inlet section 22 has a widened portion 22 a . If the smallest value 22 w (see FIG. 9 ) of the short sides of the rectangle as the cross sectional form of the filament passage 25 in the air inlet section 22 and the smallest value 21 w (see FIG. 9 ) of the short sides of the rectangle as the cross sectional form of the filament passage 25 in the steady flow section 21 are set to be different from each other, the amount of the air sucked from outside in the air inlet section 22 can be set at a desired value.
  • the air injection section 23 has air injection holes 23 a for injecting air for the numerous filaments F running in the filament passage 25 , to form an air stream for ensuring that the numerous filaments F are disposed in a straight line without overlapping each other.
  • the air injection holes 23 a have an injection angle of ⁇ against the running direction of the numerous filaments F, to ensure that the compressed air 41 a flows toward the air discharge section 24 . It is preferred that the injection angle ⁇ is 45° or less. If the injection angle ⁇ s more than 45°, the injected air may flow toward the air inlet section 22 , to disturb the running of the numerous filaments F.
  • the injection angle ⁇ be in a range of 5° to 15°.
  • the injection holes 23 a are installed on the long sides of the filament passage rectangular in the cross section shown in FIG. 7 , but the injection holes 23 a can be slits extending in the full length of the long sides 21 L of the rectangle or arrangements of plural circular holes 32 a as shown as a perspective view in FIG. 8 .
  • the spinning tube 20 can also comprises injection blocks 23 b , 23 c and the like that can be assembled and disassembled.
  • the injection angle ⁇ of the injection holes, the slit width Ei of the injection holes 23 a (or the diameter of circular holes), and the smallest values 21 w or 22 w of the short sides of the rectangle as the cross sectional form of the filament passage 25 in the air inlet section 22 or the steady flow section 21 can be easily changed to suit desired operation conditions.
  • the air inlet section 22 has a widened portion 22 a on the most upstream side (the inlet of the filament passage 25 ) as shown in FIG. 6 .
  • the sucked flow 42 a of outside air formed by the compressed air 41 a injected from the injection holes 23 a can be smoothly formed into the filament passage 25 .
  • the widened portion 22 a can be tapered or formed like a rounded trumpet.
  • the air discharge section 24 has a widened portion 24 a on the most downstream side (the outlet of the filament passage 25 ) as shown in FIG. 6 .
  • the compressed air 41 a from the air injection section 23 and the sucked flow 42 a join to form a running air stream 40 , and after it has flowed through the steady flow section 21 , it becomes discharge-destined flow 43 a at the bottom end of the air discharge section 24 , being discharged outward from the filament passage 25 .
  • the widened portion 24 a can be tapered, but it is preferred that the widened portion is curved, since the discharge-destined flow 43 a can be smoothly discharged. Furthermore, as shown in FIG.
  • suction ports 46 can be formed in the air discharge section 24 of the spinning tube 20 as shown in FIG. 10 , to positively eliminate the discharge-destined flow 43 a from the suction ports 46 using a suction blower 45 .
  • the discharge-destined flow 43 a can be prevented from flowing toward the downstream side of the bottom end of the spinning tube 20 .
  • a discharge-destined flow suction means 47 connected with a suction blower 45 can also be installed downstream of the bottom end of the spinning tube 20 and upstream of the oiling means 17 , for sucking the discharge-destined flow 43 a .
  • the cross sectional form of the passage of the discharge-destined flow suction means 47 is rectangular like the cross sectional form of the filament passage 25 of the spinning tube 20 , and that suction faces 44 a are formed on the faces parallel to the direction in which the running numerous filaments F are disposed side by side. It is also allowed that the suction ports 46 are formed in the air discharge section 24 of the spinning tube 20 as shown in FIG. 10 , and in addition, that the discharge-destined flow suction means 47 is installed as shown in FIG. 11 .
  • the spinning tube 20 In order to regulate the sucked flow 42 a formed by the spinning tube 20 , as shown in FIG. 12 , it is preferred to install flow regulation sections 31 having, for example, honeycomb-like grate members. In this constitution, the sucked flow 42 a with a predetermined direction can be formed, and a stable air stream can be given to the running numerous filaments F.
  • the flow regulation sections 31 are only required to be such that the grate members are installed in parallel to the direction in which the running numerous filaments F are disposed side by side, and if the cross sectional form of the passage in the flow regulation sections 31 is rectangular like the filament passage 25 of the spinning tube 20 , an air stream can be caused to act more uniformly on the running numerous filaments F. Furthermore, one of the grate members can be installed only on one side of the long sides of the disposed numerous filaments F, but for stabilizing the running of numerous filaments F more positively, it is preferred to install the grate members on both sides of the disposed numerous filaments F.
  • each of the grate members comprises two grate components 31 x and 31 y overlaid on each other as shown in FIG. 13 , the size of the formed holes 31 z can be adjusted to allow the flow rate of the sucked flow 42 a to be easily controlled. Furthermore, for smoothing the sucked flow 42 a , it is preferred that the top end of the air inlet section 22 of the spinning tube 20 and the bottom end of the flow regulation sections 31 are joined to be flush with each other without any difference formed at a joint 29 of FIG. 12 , to ensure that the passage in the flow regulation sections 31 and the filament passage 25 of the spinning tube 20 can be connected smoothly.
  • an air stream regulation means 30 having both the function of the flow regulation sections 31 shown in FIG. 12 and the function of regulating the temperature of the supplied air can also be installed upstream of the top end of the spinning tube 20 .
  • the air stream regulation means 30 is connected to a temperature-regulated air supply section 33 .
  • the air 32 a adjusted at a desired temperature supplied from the temperature-regulated air supply section 33 is regulated by the grate members of the flow regulation sections 31 , and is positively supplied to the running numerous filaments F. Since air adjusted at a desired temperature is supplied, the numerous filaments F existing before the spinning tube 20 are cooled, insulated or heated, depending on the situation. In this constitution, the temperature of the numerous filaments F can be controlled at a desired temperature.
  • the air 32 a can be supplied from both sides of the running numerous filaments F, but it is preferred that the temperature-regulated air is supplied to the numerous filaments F from one side, while the air used is sucked from the other side.
  • the air stream formed in the spinning tube 20 can be controlled separately from the air stream formed by the air stream regulation means 30 .
  • the volatile substance generated from the numerous filaments F can also be sucked for removal, and the contamination of the spinning tube 20 caused by the volatile substance deposited on the inside of the spinning tube 20 can also be prevented.
  • a temperature regulation means 35 can also be installed as shown in FIG. 15 for controlling the temperature of the numerous filaments F.
  • the temperature regulation means 35 comprises a temperature regulation pipe 37 shaped like a block, a rectangular temperature regulation passage 35 a formed inside the temperature regulation pipe 37 , and heating members 36 such as ceramic heaters installed in the long side 37 a direction to oppose the numerous filaments F running in the temperature regulation passage 35 a .
  • the temperature regulation means 35 is equipped with a temperature controller 38 a and a thermometer 38 , for controlling the temperature of the heating members 36 , and as a result, the temperature of the atmosphere in the temperature regulation passage 35 a can be controlled.
  • the heating members 36 are installed in the direction in which the numerous filaments F are disposed side by side in such a manner that the faces of the long sides 37 a of the temperature control pipe 37 can be flush with the faces of the long sides 21 L of the steady flow section 21 of the spinning tube 20 .
  • the temperature regulation means 35 can also be cylindrical in appearance as shown in FIG. 16 , if the temperature regulation passage 35 a of the temperature regulation pipe 37 through which the numerous filaments F pass have a rectangular outlet 39 a.
  • Both the air stream regulation means 30 shown in FIG. 14 and the temperature regulation means 35 shown in FIG. 15 can also be used together to control the temperature of the numerous filaments F existing upstream of the top end of the spinning tube 20 .
  • the top end face of the air stream regulation means 30 or the temperature regulation means 35 and the bottom end face of the spinneret 12 or the spinning block 11 are connected with each other to achieve air tightness, for preventing that the outside air flows through the clearance between such a means and the spinneret 12 for disturbing the air stream in the inside filament passage and to prevent that the spinneret 12 is cooled.
  • the air supply device 41 for the spinning tube 20 shown in FIG. 6 and the suction ports 46 formed in the air discharge section 24 shown in FIG. 10 (or the discharge-destined flow suction means 47 shown in FIG. 11 ) can also be connected with each other, to use the compressed air 41 a supplied to the spinning tube 20 in circulation.
  • an air controller 49 for controlling, for example, the temperature and the flow rate should be installed, and the signal of the air controller 49 should be used to adjust the opening of a valve 41 y of a supply pipe 41 x , for example in the case where the flow rate of the compressed air 41 a is insufficient.
  • the air recovered from the suction ports 46 of the air discharge section 24 (or the discharge-destined flow suction means 47 shown in FIG. 11 ) can be fed through a bypass pipe 48 for supply again to the air stream regulation means 30 as supply air 32 a.
  • FIG. 18 shows a spinning apparatus, in which a gas suction device 60 is installed immediately below the spinneret 12 , and the spinning tube 20 spaced from the bottom end of the gas suction device 60 is installed below the gas suction device 60 .
  • the gas suction device 60 is installed between the spinneret 12 and the spinning tube 20 detachably from the spinning apparatus.
  • the gas suction device 60 sucks the gas containing the volatile substance generated from the numerous filaments F composed of a polymer discharged from the spinning holes 13 of the spinneret 12 .
  • the gas suction device 60 comprises suction buffers 61 and gas suction ports 62 composed of gas permeable grate members.
  • the gas suction ports 62 are installed on both sides of the row of the numerous filaments F composed of a polymer discharged from the spinneret 12 , to face the numerous filaments F in parallel to them.
  • the suction buffers 61 are connected with a gas suction blower 63 for carrying the gas sucked from the gas suction ports 62 to outside the apparatus, through a volatile substance collection filter 64 .
  • the volatile substance collection filter 64 removes the volatile substance contained in the sucked gas, and the remaining gas is discharged from the gas suction blower 63 to the atmosphere.
  • the gas suction device 60 If the gas suction device 60 is positioned with its top face kept as close to the bottom face of the spinneret 12 as possible, the gas can be effectively sucked. However, if the top face of the gas suction device 60 contacts the bottom face of the spinneret 12 , the gas suction device can cool the spinneret 12 . So, it is preferred that the clearance between the bottom face of the spinneret 12 and the top face of the gas suction device 60 (the distance between both in the vertical direction) expressed by SL satisfies a relation of SL ⁇ 2 mm.
  • the gas suction ports 62 are formed in planes parallel to the row of the numerous filaments F. If the gas suction ports 62 are closer to the row of the numerous filaments F, the gas suction efficiency is higher. However, if they are too close, the gas flow caused by suction causes the numerous filaments F to be swung greatly, and it may happen that the numerous filaments F are fused to each other. If the suction distance from the gas suction ports 62 to the row of the numerous filaments F is PL, it is preferred to satisfy a relation of 2 mm ⁇ PL ⁇ 20 mm.
  • flow regulation members low in gas flow resistance such as honeycomb members as the gas suction ports 62 for regulating the flow of sucked gas.
  • the amounts of sucked gas can be adjusted to desired flow rates by means of the suction adjusting valves 65 . It is desirable to use flow meters 66 provided for measuring both the flow rates, to equalize the flow rates of the gas sucked by both the suction ports 62 . In this constitution, the numerous filaments F can be prevented from swinging.
  • the flow rate can be controlled easily based on the correlation between the values indicated by a negative pressure gauge 67 and the gas velocities measured beforehand at the gas suction port 62 .
  • the gas suction velocity can be very small. Though depending on the distance between the gas suction ports 62 and the numerous filaments F, it is preferred that the gas suction velocity is in a range of 5 m/min to 30 m/min. Since the running speed of the numerous filaments F on the more downstream side is higher, it is desirable to adjust the gas suction ports 62 for ensuring that the suction flow rates on the downstream side become higher than those on the upstream side in the gas suction device 60 . In this constitution, the gas accompanying the running numerous filaments F can be efficiently collected.
  • the gas suction device 60 sucks the gas existing around the numerous filaments F, there occurs a phenomenon that the outside air is sucked from the surrounding. In this phenomenon, the incoming outside air lowers the temperature around the spinneret 12 , and as a result, the spinnability may be impaired.
  • the suction buffers 61 of the gas suction device 60 spaced from the spinneret 12 as shown in FIG. 21 . This can be achieved if the top faces of the suction buffers 61 are kept in contact with the bottom face of the spinning block 11 directly or indirectly through a packing lip. As a further other means, for example, the clearance between the bottom face of the spinning block 11 and the top faces of the suction buffers 61 can be perfectly closed by means of the packing 11 p . In this constitution, the space between the bottom face of the spinneret 12 and the top face of the gas suction device 60 is kept gas-tight.
  • FIG. 22 is a sectional view of the suction device 60 in the direction perpendicular to the direction vertical to the bottom face of the spinneret 12 (the direction perpendicular to the running direction of the numerous filaments F in the case where the numerous spinning holes 13 of the spinneret 12 are arranged on one straight line).
  • the gas suction device 60 sucks the outside air from both the lateral sides 62 a open to the outside air of the gas suction ports 62 .
  • the gas suction device 60 sucks the gas positioned around the filaments F running on both lateral sides of the numerous filaments F more strongly than the gas positioned around the filaments F running inside among the numerous filaments F.
  • the produced numerous filaments constituting a yarn become different from each other (irregular) in properties.
  • flow regulation sections 31 each having a honeycomb grate member 88 as shown in FIG. 24 , between the bottom face of the gas suction device 60 and the top face of the spinning tube 20 , for regulating the inflow direction.
  • the outside air 81 a incoming from suction spaces 80 forms an ascending stream against the running direction of the numerous filaments F. Because of the ascending stream, the gas otherwise destined to flow down accompanying the running numerous filaments F is turned toward the gas suction device 60 , and collected by the gas suction device 60 . As a result, the inflow of the gas generated near the spinneret 12 into the spinning tube 20 installed downstream of the gas suction device can be prevented.
  • the flow regulation sections 31 each having the suction space 80 is installed between the bottom end of the gas suction device 60 and the top end of the spinning tube 20 , the sucked flow 42 a caused by the spinning tube 20 is also regulated in the downstream portion in the flow regulation sections 31 .
  • the sucked flow 42 a directed as desired is allowed to flow into the filament passage 25 of the spinning tube 20 .
  • a stable air stream with a small volatile matter content flows into the filament passage 25 of the spinning tube 20 .
  • the flow regulation sections 31 are provided with grate members 88 arranged with their longitudinal direction kept in parallel with the direction in which the running numerous filaments F are disposed side by side.
  • the cross sectional form of the filament passage in the flow regulation sections 31 can be rectangular like the cross sectional form of the filament passage 25 in the spinning tube 20 . In this constitution, the air stream can be caused to more uniformly act on the running numerous filaments F.
  • suction spaces 80 of the flow regulation sections 31 are provided on both sides of the disposal of the numerous filaments F, to further stabilize the running of the numerous filaments F.
  • the grate members 88 installed in the flow regulation sections 31 are installed to ensure that the air streams are regulated in the direction perpendicular to the direction in which the numerous filaments F are disposed side by side, in planes perpendicular or inclined to the disposal faces of the numerous filaments F (for example, the disposal faces of the numerous filaments F formed by the row of spinning holes indicated by the straight line Z in FIG. 5A ).
  • the inclination angle can also change from the top ends to the bottom ends of the grate members 88 .
  • FIG. 24 is a perspective view showing either of the grate members 88 used in the flow regulation sections 31 and also the thickness 88 t of the grate member 88 in the flow regulation direction. If the thickness 88 t in the flow regulation direction is larger, the flow regulation effect is higher. It is preferred that the grate member 88 is formed to have a thickness 88 t of 5 mm or more.
  • the flow regulation sections 31 can also be connected with a blower 33 as shown in FIG. 25 .
  • the blower 33 positively supplies air to the flow regulation sections 31 of the suction spaces 80 , to assist the flow of the outside air 81 a flowing toward the suction device 60 and the flow of the sucked flow 42 a flowing toward the spinning tube 20 .
  • an inert gas such as nitrogen can also be introduced.
  • Hot air or cold air can also be introduced to control the temperature of the air acting on the numerous filaments F.
  • a filament break sensor 96 is installed between the second godet roller 15 and the winding means 16 .
  • the filament break sensor 96 detects it and issues a filament break detection signal.
  • a sucker 95 is installed between the spinning tube 20 and the oiling means 17 , to face the running passage of the yarn Y consisting of numerous filaments F.
  • the sucker 95 is connected with a waste yarn blower 94 . If the waste yarn blower 94 is actuated based on a filament break detection signal, the sucker 95 sucks the yarn Y.
  • the numerous filaments F continuously formed by the spinning holes 13 of the spinneret 12 keep running on the upstream side of the position where the breaking has occurred.
  • the numerous filaments F continuously running from the spinneret 12 are sucked and taken up by the waste yarn blower 94 and the sucker 95 respectively actuated based the filament break detection signal issued by the filament break sensor 96 when the sensor has detected the breaking.
  • the yarn taken up by the sucker 95 is discharged from the sucker 95 and accommodated in a waste yarn container 97 . In this constitution, the winding of the yarn around the first godet roller 14 and the second godet roller 15 is prevented.
  • the sucker 95 is installed in such a manner that it opens toward the air discharge section 24 of the spinning tube 20 and can move horizontally in the direction in which the numerous filaments F are disposed side by side (the long side direction of the filament passage 25 of the spinning tube 20 ).
  • the air supply device 41 injects the compressed air 41 a obliquely downward into the filament passage 25 of the spinning tube 20 from the injection holes 23 a . As a result, the air stream 40 running downward in the filament passage 25 is formed.
  • the spinning tube 20 is installed below the spinneret 12 in the vertical direction in such a manner that the numerous filaments F composed of a polymer discharged as a row(s) from the numerous spinning holes 13 of the spinneret run straight downward in the vertical direction through the filament passage 25 of the spinning tube 20 .
  • the sucked flow 42 a formed in the air inflow section 22 allows the filaments F to be easily introduced into the filament passage 25 , and further allows the filaments F to easily pass through the filament passage 25 . If the elevator 26 is actuated to lower the spinning tube 20 , the filaments F run stably and can easily pass through the filament passage 25 .
  • a flowable polymer is discharged from the numerous spinning holes 13 arranged in a row(s) in the spinneret 12 provided in the spinning block 11 .
  • the discharged polymer forms numerous filaments F disposed in accordance with the arranged spinning holes 13 .
  • the formed numerous filaments F are introduced into the inlet of the filament passage 25 , and are discharged from the outlet of the filament passage 25 .
  • the polymer constituting the numerous filaments F loses its flowability and is solidified while it passes through the filament passage 25 of the spinning tube 20 .
  • the filaments F discharged from the filament passage 25 are fed along the oiling means 17 , the first godet roller 14 and the second godet roller 15 sequentially, finally being wound by the winder 16 .
  • the initial work in the production of yarn Y is completed.
  • the operation of the suction blower 45 connected with the suction ports 46 is suspended till the yarn installation work up to the winder 16 is completed, and after the yarn installation work has been completed, the suction blower 45 is actuated.
  • the polymer is continuously discharged from the spinning holes 13 of the spinneret 12 , to form numerous filaments F.
  • the injection holes 23 a formed in the spinning tube 20 toward the filament passage 25 air streams are injected obliquely downward toward the formed numerous filaments F on both sides of the numerous filaments F. Receiving the air streams, the numerous filaments F are disposed in one row without overlapping each other.
  • the disposed numerous filaments F run downward in the filament passage 25 with the disposal maintained.
  • the air streams injected from the injection holes 23 a obliquely downward into the filament passage 25 for contribution to the maintenance of the disposal of the numerous filaments F form a downward running air stream 40 in the filament passage 25 .
  • the downward running numerous filaments F and the downward running air stream 40 coexist.
  • the coexistence of the running numerous filaments F and the running air stream 40 in the filament passage 25 allows that the numerous filaments F composed of a polymer discharged from the spinning holes 13 are stably drawn and made thinner. As a result, a high elongation yarn Y having little irregularity among the filaments can be produced at a high speed.
  • the numerous filaments F composed of a polymer discharged from the spinning holes 13 , not yet solidified, are introduced into the filament passage 25 of the spinning tube 20 , and are drawn and made thinner there. Therefore, unlike a nonwoven fabric obtained by cooling and solidifying the numerous filaments composed of a polymer discharged from the spinning holes and drawing them with an air stream, a high elongation yarn having little irregularity among the filaments can be produced.
  • the running velocity Ve of the running air stream 40 flowing in the steady flow section 21 is kept at not less than a velocity of 60% of the yarn take-up speed Vw.
  • the running velocity Ve of the running air stream 40 is not more than a velocity of 120% of the yarn take-up speed Vw.
  • the speed Vf of the filaments F composed of a polymer discharged at an initial speed of Vo from the spinning holes 13 becomes gradually higher with the increase of distance from the spinneret 12 in the vertical direction, and it reaches the yarn take-up speed Vw at a certain point.
  • FIG. 27 This relation is shown in FIG. 27 .
  • the distance from the bottom face of the spinneret 12 in the vertical direction is chosen as the abscissa, and the speed of the filaments F at each distance from the bottom face of the spinneret 12 in the vertical direction is chosen as the ordinate.
  • the speed of the filaments F changes as shown by curve A in the graph of FIG. 27 .
  • the filaments F can be made thinner in the upstream region in the filament passage 25 .
  • This constitution facilitates the production of a non-oriented yarn Y, i.e., a high elongation yarn Y.
  • the atmosphere temperature upstream of the spinning tube 20 can be positively controlled.
  • the atmosphere in the temperature regulation passage 35 a through which the numerous filaments F run can be controlled by radiation heat. This allows the temperature of the numerous filaments F entering the spinning tube 20 to be controlled at a desired temperature. This temperature control facilitates the production of a yarn Y having desired physical properties.
  • the temperature of the filaments F entering the filament passage 25 of the spinning tube 20 is 160° C. or higher. A more preferred temperature is 200° C. or higher. If the temperature of the filaments F is controlled to such a temperature, the injection flow rate Ef of the air injected into the filament passage 25 from the air supply device 41 can be decreased to lower the production cost of the yarn Y.
  • the filament break sensor 96 detects the filament breaking as shown in FIG. 26 , and the drive of the drive system ranging from the first godet roller 14 to the winder 16 is stopped. At the same time, the waste yarn blower 94 is actuated, and the waste yarn sucker 95 sucks the filaments coming from the filament passage 25 as waste filaments F 1 while being reciprocated in the direction in which the numerous filaments F are disposed side by side (horizontal direction). It is preferred that while the filament breaking situation is dealt with like this, the injection flow rate Ef of the compressed air 41 a into the spinning tube 20 is decreased more or less compared with the normal flow rate.
  • the numerous filaments F When the numerous filaments F are oiled, the numerous filaments F can be bundled as one yarn, but instead, as shown in FIG. 28 , an oiling means consisting of a long oil supply roller 17 a and an oil coating member 17 b for applying an oil to the oil supply roller 17 a can also be used for applying an oil to each of the filaments.
  • the spinneret installed in the spinning block 11 can also have plural spinning hole groups 13 a , each consisting of plural spinning holes 13 , arranged in one direction.
  • plural spinnerets 12 arranged in one direction, each having plural spinning holes 13 arranged in the same one direction, can also be used.
  • the plural yarns YY can pass through one spinning tube 20 , and further along the roller 17 a of one oiling means.
  • Eyy corresponds to (Ey) ⁇ (number of yarns).
  • the properties of the yarn obtained at a production speed of 3,000 m/min or 4,000 m/min by a conventional method can be realized even at a speed of 5,000 m/min or more.
  • the production speed can also be 6,000 min/min to 10,000 m/min even in the case where it is intended to obtain a yarn with similar properties.
  • the yarn production method of the invention satisfies both the quality and productivity of the obtained yarn in good balance, compared with the yarn production methods of the prior art. Therefore, the yarn production method of the invention can also be used, for example, for producing a very thin yarn with a filament fineness of 0.5 dtex or less difficult in the control of yarn quality, and also for producing a monofilament.
  • the gas suction blower 63 is operated to produce a state in which the gas suction device 60 can suck the gas in the filament passage in the gas suction device 60 .
  • the air supply device 41 is operated to inject the compressed air 41 a into the filament passage 25 of the spinning tube 20 from the two injection holes 23 a opened to face each other in the filament passage 25 , and the air streams injected from both the injection holes 23 a collide with each other in the filament passage 25 , to form a air stream 40 running downward in the filament passage 25 .
  • the spinning tube 20 is positioned below the spinneret 12 in the vertical direction, to ensure that the numerous filaments F composed of a polymer discharged as a row from the spinning holes 13 of the spinneret 12 can run straight downward in the vertical direction, to pass through the filament passage 25 of the spinning tube 20 .
  • the sucked flow 42 a formed in the air inlet section 22 allows the filaments F to be easily introduced into the filament passage 25 , and facilitates further passage of the filaments F through the filament passage 25 .
  • the elevator 26 is actuated to move the spinning tube 20 further downward from the spinneret 12 , the filaments F are progressively cooled and solidified, to facilitate their passage through the filament passage 25 , and at the same time, the gas near the spinneret 12 generated from the filaments F is sucked into the filament passage 25 of the spinning tube 20 and discharged outside in the time zone before start of normal operation (before yarn threading). So, the contamination in the spinning tube 20 by the gas containing the volatile substance can be avoided. Furthermore, the running of the filaments F can be stabilized to allow easy passage through the filament passage 25 .
  • the gas suction device 60 can also be connected at the top of the spinning tube 20 , to ensure that it can be lowered or lifted together with the spinning tube 20 .
  • the gas suction device 60 is separate from the spinning tube 20 and installed on the under face of the spinning block 11 or the spinneret 12 , the clearance of the suction spaces 80 ( FIG. 23 ) can be easily adjusted at a desired distance by lifting or lowering the spinning tube 20 .
  • a polymer is discharged from the spinning holes 13 arranged in a row in the spinneret 12 installed in the spinning block 11 , to form numerous filaments F.
  • the formed numerous filaments F pass through the filament passage 25 of the gas suction device 60 and the spinning tube 20 .
  • the running filaments F are solidified while they pass through the filament passage 25 of the spinning tube 20 .
  • the solidified filaments F are sucked by a suction gun (not illustrated), and guided along the oiling means 17 , the first godet roller 14 and the second godet roller 15 sequentially, being finally wound by the winder 16 .
  • a suction gun not illustrated
  • the polymer is discharged continuously from the spinneret 12 , to form numerous filaments F, and the formed numerous filaments F run downward in the filament passage 25 of the gas suction device 60 and the spinning tube 20 with their disposal maintained.
  • the gas suction device 60 sucks the gas generated from the filaments F.
  • the compressed air 41 a injected from the injection holes 23 a acts on the numerous filaments F running through the filament passage 25 of the spinning tube 20 , and the numerous filaments F are aligned along a straight line without overlapping each other.
  • the numerous filaments F running in the filament passage 25 are cooled and solidified while they pass through the filament passage 25 .
  • the cooled and solidified numerous filaments F are bundled and oiled by the oiling means 17 .
  • the oiled numerous filaments F are guided as the yarn Y along the first godet roller 14 and the second godet roller 15 , being wound around a bobbin by the winder 16 .
  • the yarn Y is produced as a yarn package.
  • the yarn production method satisfies both yarn quality and yarn productivity in good balance compared with the yarn production processes of the prior art.
  • the yarn production process can also be used for producing a yarn consisting of numerous filaments composed of any of various polymers such as polypropylene and polylactic acid.
  • This yarn production process can be used for producing a very thin yarn with a filament fineness of 0.5 dtex or less, or difficult in the control of yarn quality, and also for producing a thick yarn such as a monofilament.
  • yarn production methods using the yarn production apparatus shown in FIG. 4 are described below, and as comparative examples, yarn production methods using the apparatus shown in FIG. 1 are described.
  • the production conditions used in the examples and comparative examples are shown in the following respective tables.
  • the spinning tube 20 used in Examples 1 through 13 is shown in FIG. 6 .
  • the cross sectional view of the spinning tube 20 and its filament passage 25 is shown in FIG. 7 .
  • the cross sectional form of the filament passage 25 is rectangular.
  • the spinning tube 20 had the air inlet section 22 , the air injection section 23 , the steady flow section 21 and the air discharge section 24 , to name from the top end to the bottom end.
  • the air inlet section 22 had a widened portion 22 a
  • the air discharge section 24 had a widened portion 24 a .
  • the length Ex of the short sides 21 S in the cross section of the filament passage 25 in the steady flow section 21 was 2 mm, and the length Ey of the long sides 21 L was 100 mm.
  • the running air stream velocity Ve (m/min) of the running air stream 40 flowing in the steady flow section 21 was obtained from the following formula based on the differential pressure Po between the respective pressures obtained from the pressure pipe P 1 installed in the wall of the steady flow section 21 and the pressure pipe P 2 installed in the downstream region of the air discharge section 24 .
  • Ve (2 ⁇ Po/p) 1/2 where p is the density of air.
  • the filament speed Vf (m/min) of the filaments F running between the spinneret 12 and the first godet roller 14 was measured using the measuring instrument shown in FIG. 32 .
  • a laser Doppler yarn velocimeter 50 consisted of a measuring head 51 and a controller 52 .
  • the measuring head 51 was moved in the running direction of the filaments F, and the filament speed Vf (m/min) of the filaments F running between the spinneret 12 and the first godet roller 14 was measured at every 100 mm position from the spinneret 12 .
  • the spinning tube 20 was partially opened at a portion corresponding to one short side 21 b of the filament passage 25 so that the laser beam could reach the inside of the filament passage 25 from the measuring head 51 when the yarn speed was measured.
  • the opening affects the air stream of the filament passage 25
  • the opening should be given up, and a small hole for allowing the transmission of the laser beam for measurement should be formed in the spinning tube 20 at a portion corresponding to one short side 21 S of the filament passage 25 .
  • a portion of the spinning tube 20 corresponding to one short side 21 S of the filament passage 25 should be made of a material capable of transmitting the laser beam for measurement, to allow measurement through the portion.
  • L 1 (mm) indicates the distance from the bottom face of the spinneret 12 to the top face of the spinning tube 20 , and defines the spinning tube position.
  • L 2 (mm) indicates the overall length of the spinning tube 20 , and defines the spinning tube length.
  • L 3 (mm) indicates the distance from the bottom face of the spinneret 12 to the oiling means 17 , and defines the oiling position.
  • L 4 (mm) indicates the distance from the bottom face of the spinneret 12 to the first godet roller 14 , and defines the take-up position.
  • Vw (m/min) indicates the yarn Y take-up speed by the first godet roller 14 .
  • Es (mm) indicates the distance from the top face of the spinning tube 20 to the injection holes 23 a of the air injection section 23 (the center of the open faces of the injection holes 23 a in the vertical direction on the wall faces of the filament passage 25 ), and defines the slit position.
  • the distance between the respectively adjacent spinning holes 13 is expressed as the spinning hole pitch P (mm)
  • the hole diameter of the spinning holes 13 on the bottom face of the spinneret 12 is expressed as the spinning hole diameter d (mm)
  • the center distance between the two spinning holes most apart from each other among the plural spinning holes 13 is expressed as distance dw (mm) between the outermost spinning holes.
  • the apparatus shown in FIG. 4 was used to produce polyester yarns Y each consisting of 36 filaments F with a filament fineness D of 135 dtex under the conditions shown in Table 1.
  • the spinneret 12 used had all the spinning holes 13 , i.e., 36 spinning holes 13 arranged on a straight line Z as shown in FIG. 5A .
  • the spinning hole pitch P was 2.5 mm and the spinning hole diameter d was 0.3 mm.
  • the distance dw between the outermost spinning holes was 90.3 mm.
  • Example 1, 2, 3 and 4 the same conditions were employed except that the spinning tube position L 1 was changed.
  • the yarn production conditions and the properties of the obtained yarns are shown together in Table 1 given later.
  • the swing of the 36 filaments F running upstream and downstream of the spinning tube 20 was small, and a good spinning state could be observed. It was confirmed that the 36 filaments F maintained their disposal obtained immediately after they had been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and passed through the spinning tube 20 without being converged (without contacting each other).
  • Example 1 The results of yarn quality evaluation of the yarn Y wound by the winding means 16 are shown in Table 1.
  • the yarn properties in Example 1 were 141% in elongation E, 2.4 g/dtex in strength T and 0.95 in yarn irregularity U%.
  • Those in Example 2 were 128% in elongation E, 2.6 g/dtex in strength and 0.93 in yarn irregularity U%.
  • Those in Example 3 were 104% in elongation E, 2.8 g/dtex in strength T and 1.00 in yarn irregularity U%.
  • Those in Example 4 were 86% in elongation E, 3.0 g/dtex in strength T and 1.13 in yarn irregularity U%.
  • the filament velocity Vf of the running filaments F was measured at every 100 mm position from the spinneret 12 , and the results are shown in FIG. 33 .
  • the distance from the spinneret 12 to the point at which the solidified filaments F reached the take-up speed Vw was identified as the take-up speed reaching point Lg, and the distance from the spinneret 12 to the middle point between the two points of the largest gradients in the curve formed by connecting the measuring points was identified as the acceleration point.
  • the results of these points in the respective examples are shown in Table 2 given later.
  • the temperature Ti(0° C.) of the filaments F at right above the air inlet section 22 of the spinning tube 20 was measured using a non-contact type thermometer in each example. The results are shown in Table 2.
  • the temperatures Ti in the respective examples were 215° C. in Example 1, 203° C. in Example 2, 184° C. in Example 3 and 158° C. in Example 4.
  • the results mean that if the value of the spinning tube position L 1 is smaller, the filaments with a higher temperature enter the spinning tube 20 .
  • the filaments F While the filaments F are kept at a high temperature, the filaments F encounter the compressed air 41 A injected obliquely downward toward the running direction of the filaments F from the injection holes 23 a , and thereafter, together with the running air stream 40 running downward in the filament passage 25 , the filaments run downward in the filament passage 25 .
  • the coexistence of the filaments F and the running air stream 40 allows the produced yarn Y to have a higher elongation.
  • the yarn Y obtained like this can have an elongation of not less than 1.5 times the elongation of the yarn obtained in Comparative Example 1 described later.
  • the respective acceleration points La are within the spinning tube range Le in Examples 1 through 4, and the values VL of the filament speed Vf at the acceleration points La are smaller than the values of the running air stream velocity Ve. This means that at least partially in the spinning tube 20 , the drawing force of the running air stream 40 acted on the filaments F.
  • the apparatus shown in FIG. 1 was used to produce polyester yarns Y each consisting of 36 filaments F with a filament fineness D of 135 dtex under the conditions shown in Table 3.
  • the spinneret 1 shown in FIG. 2 was used.
  • the spinneret 1 had 36 spinning holes 6 so arranged within a circle having a diameter dd of 72 mm that the filaments discharged from the holes should not contact each other.
  • the cooling means 3 shown in FIG. 1 supplied cooling air 3 a to the downward running filaments F composed of a polymer discharged from the spinning holes 6 of the spinneret 1 , in the direction perpendicular to the vertical direction.
  • the filament cooling length L 22 in the cooling means was 1,000 mm, and the cooling air velocity Vc 1 of the cooling air 3 a was 30 m/min.
  • the cooling air 3 a was blown from the cooling air blow face of the cooling means 3 and crossed the running filaments F, then being sent substantially in the same direction as the blow direction and discharged out of the cooling means 3 . Therefore, there was no air stream that ran in the running direction of the filaments F and dominated the running filaments F.
  • L 11 indicates the distance from the bottom face of the spinneret 1 to the top face of the cooling means 3 , and defines the cooling means position.
  • Comparative Examples 1, 2 and 3 employed the same conditions except that the yarn take-up speed Vw was changed. The yarn production conditions and the properties of the obtained yarns in these comparative examples are shown together in Table 3 given later.
  • the swing of the running 35 filaments upstream and downstream of the cooling means 3 was small. However, it was confirmed that the cooling air 3 a crossing the filaments F in the direction substantially perpendicular to the running direction of the filaments F bent the running filaments F. The bending degree was different from filament to filament depending on the respective running positions resulting from the positions of the arranged spinning holes 6 .
  • the results of yarn quality evaluation of the yarns Y wound by the winding means 5 are shown in Table 3.
  • the yarn properties in Comparative Example 1 were 65% in elongation E, 3.1 g/dtex in strength T and 1.24 in yarn irregularity U%.
  • Those in Comparative Example 2 were 98% in elongation E, 2.9 g/dtex in strength T and 1.13 in yarn irregularity U%.
  • Those in Comparative Example 3 were 119% in elongation E, 2.7 g/dtex in strength T and 1.05 in yarn irregularity U%. It was confirmed that when the yarn take-up speed Vw was higher, the elongation E of the produced yarn was smaller.
  • Example 1 In comparison with Examples 1 through 4, the examples could produce high strength yarns even at a yarn take-up speed Vw of 5,000 m/min. Especially Example 1 could produce a yarn with an elongation higher than that of Comparative Example 3 in which the take-up speed Vw was 3,500 m/min.
  • the filament speed Vf of the running filaments F was measured at every 100 mm position from the spinneret 1 , and the results are shown in FIG. 34 .
  • the reaching points Lg and the acceleration points La are shown in Table 4 given later.
  • FIG. 34 shows that the increase of take-up speed Vw changed both the position of the reaching point Lg (reaching points Lg 1 x to Lg 3 x) and the position of the acceleration point (acceleration points La 1 x to La 3 x) toward the downstream side.
  • the position of every acceleration point La was on the downstream side of one half of the distance to the position of the corresponding reaching point Lg. That is, the comparative examples showed a relation of acceleration point La>reaching point Lg/2 irrespective of the take-up speed Vw.
  • Example 5 and Comparative Example 4 the apparatus shown in FIG. 4 was used to produce polyester yarns each consisting of 36 filaments F with a filament fineness D of 135 dtex as described for Example 1, except that the injection flow rate Ef, the injection velocity Vs and the running air stream velocity Ve were changed as shown in Table 5 given later.
  • the yarn production conditions and the properties of the obtained yarns in Example 5 and Comparative Example 4 are shown in Table 5 given later.
  • Example 5 the swing of the running 36 filaments F in the positions upstream and downstream of the spinning tube 20 was small, and a good spinning state was observed. It was confirmed that the 36 filaments F maintained the disposal of filaments F as achieved immediately after having been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and that the filaments F passed through the spinning tube 20 without being converged (without contacting each other).
  • Example 1 The results of yarn quality evaluation of the yarns Y wound by the winding means 16 are shown in Table 5.
  • the yarn properties in Example 1 were 141% in elongation E, 2.4 g/dtex in strength T and 0.95 in yarn irregularity U% at an injection velocity Vs of 6,000 m/min and a running air stream velocity Ve of 4,250 m/min.
  • those in Example 5 were 112% in elongation E, 3.2 g/dtex in strength T and 1.01 in yarn irregularity U% at an injection velocity Vs of 4,900 m/min and a running air stream velocity Ve of 3,240 m/min.
  • Example 1 The filament speed Vf of the running filaments F at every 100 mm position from the spinneret was measured, and the results are shown in FIG. 35 .
  • the reaching points Lg and the acceleration points La of Example 5 and Comparative Example 4 are shown in Table 6 given later.
  • Example 6 a polyester yarn consisting of 36 filaments F with a filament fineness D of 135 dtex was produced as described for Example 1, except that the steady flow section of the spinning tube 20 was extended to change the spinning tube length L 2 .
  • Example 7 a polyester yarn consisting of 36 filaments F with a filament fineness D of 135 dtex was produced as described for Example 6, except that the injection flow rate Ef and the injection velocity Vs were adjusted to ensure that the running air stream velocity Ve became virtually equal to that of Example 1 (6,200 m/min).
  • the yarn production conditions and the properties of the obtained yarns in these examples are shown together in Table 7 given later.
  • the swing of the running 36 filaments F in the positions upstream and downstream of the spinning tube 20 was small, and a good spinning state was observed. It was confirmed that the 36 filaments F maintained the disposal of the filaments F as achieved immediately after having been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and that the filaments F passed through the spinning tube 20 without being converged (without contacting each other).
  • Example 6 The yarn properties of Example 6 were 128% in elongation E, 2.7 g/dtex in strength T and 0.80 in yarn irregularity U% at a running air stream velocity Ve of 3,680 m/min. Compared with Example 1, the value of yarn irregularity U% was improved. However, though the injection flow rate Ef was equivalent to that of Example 1, it is considered that the pressure resistance caused by the longer steady flow section 21 lowered the running air stream velocity Ve and also decreased the sucked flow 42 a of the spinning tube 20 , to lower the total flow rate of the running air stream 40 , thus lowering the running air stream velocity Ve and lowering the elongation of the obtained yarn.
  • Example 7 The yarn properties of Example 7 were 140% in elongation E, 2.4 g/dtex in strength T and 0.82 in yarn irregularity U% at a running air stream velocity Ve of 4,200 m/min. Compared with Example 1, the elongation E was equivalent and the yarn irregularity U% was better. These results suggest that a longer spinning tube length L 2 can inhibit the disturbance of the filaments F running in the spinning tube 20 , and that a running air stream velocity Ve equivalent to or higher than the take-up speed Vw is a factor capable of greatly improving the elongation of the yarn. These effects can also be obtained by adjusting the length of the bottom end section 24 N of the spinning tube 20 of FIG. 9 .
  • the spinneret 12 used in Example 8 had numerous spinning holes 13 arranged in two straight lines Z 1 and Z 2 as shown in FIG. 5B .
  • the length Ey of the long sides 21 L in the cross section of the steady flow section 21 of the spinning tube 20 was changed to one half of the Ey value of Example 1.
  • the same yarn production apparatus as used in Example 1 was used except that the injection flow rate Ef and the injection velocity Vs were adjusted to achieve a running air stream velocity Ve equivalent to that of Example 1.
  • Polyester yarns each consisting of 36 filaments F with a filament fineness D of 135 dtex were produced.
  • polyester yarns each consisting of 36 filaments F with a filament fineness D of 135 dtex were produced as described for Example 8, except that the injection angle ⁇ of the injection holes 23 a in the spinning tube 20 was changed as shown in Table 8 given later.
  • the yarn production conditions and the properties of the obtained yarns in these examples are shown together in Table 8 given later.
  • the swing of the running 36 filaments F in the positions upstream and downstream of the spinning tube 20 was small, and a good spinning state was observed. It was confirmed that the 36 filaments F maintained the disposal of the filaments F as achieved immediately after having been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and that the filaments F passed through the spinning tube 20 without being converged (without contacting each other).
  • a yarn was produced under the same conditions as in Example 8, except that the spinneret used had the spinning holes 13 arranged in straight lines Z 1 and Z 2 to overlap each other on the projection drawing of the spinneret, in an attempt to evaluate the yarn similarly. However, in this case, a phenomenon occurred, in which the filaments F entering the spinning tube 20 fused each other in the upstream region of the spinning tube 20 . Since filament breaking and fluffing occurred in the yarn, the yarn was not taken up for evaluation.
  • Example 8 The results of yarn quality evaluation of the yarns Y wound by the winding means 16 are shown in Table 8.
  • the yarn properties of Example 8 were 140% in elongation E, 2.4 g/dtex in strength T and 0.98 in yarn irregularity U%. It was found that a yarn with the same quality as that of Example 1 was obtained. It was confirmed that even in the case where the spinneret 12 has spinning holes 13 arranged in two rows, if the spinning holes 13 are positioned to avoid overlapping in the direction perpendicular to the respective straight lines Z 1 and Z 2 , the intended yarn could be produced without any problem.
  • the length Ey of the long sides of the filament passage 25 of the spinning tube 20 can be shortened.
  • the length Ey becomes about one half of the length needed when they are arranged in one row, if the number of filaments F and the filament fineness D are identical.
  • the injection flow rate Ef can be decreased to reduce the production cost needed for compressed air consumption.
  • Example 9 The properties of the wound yarns were evaluated. Those of Example 9 were 143% in elongation E, 2.4 g/dtex in strength T and 0.91 in yarn irregularity U% at a running air stream velocity Ve of 4,780 m/min. Those of Example 10 were 145% in elongation E, 2.3 g/dtex in strength T and 0.88 in yarn irregularity U% at a running air stream velocity Ve of 5,230 m/min. That is, it was confirmed that if the injection angle ⁇ is smaller, a good quality yarn with an elongation equivalent or higher than that of Example 9 could be obtained.
  • a polyester yarn consisting of 36 filaments F with a filament fineness D of 135 dtex was produced as described for Example 1 under the conditions shown in Table 9 given later, except that an apparatus as shown in FIG. 12 was used, in which flow regulation sections 31 having air regulation plates were installed upstream of the spinning tube 20 .
  • the air regulating boards were honeycomb grates installed on both sides of the filaments F at a position immediately above the air inlet section 22 of the spinning tube 20 .
  • the size of each flow regulation section 31 was 60 mm in length Lc and 10 mm in thickness Lt.
  • the yarn production conditions and the properties of the obtained yarn of Example 11 are shown together in Table 9 given later.
  • Example 11 the swing of the running 36 filaments F in the positions upstream and downstream of the spinning tube 20 was small, and a good spinning state was observed. It was confirmed that the 36 filaments F maintained the disposal of the filaments F as achieved immediately after having been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and that the filaments F passed through the spinning tube 20 without being converged (without contacting each other).
  • the yarn properties of the wound yarn Y were evaluated and found to be 143% in elongation E, 2.4 g/dtex in strength T and 0.85 in yarn irregularity U%. Compared with Example 1, since the air regulation plates regulated the sucked flow 42 a , it could be visually confirmed that the swing of the filaments F in the position upstream of the spinning tube 20 was smaller than that in Example 1, and that because of it, the yarn irregularity could be further improved.
  • Polyester yarns each consisting of 36 filaments F with a filament fineness D of 135 dtex were produced under the conditions shown in Table 10 given later, as described for Example 1, except that, as shown in FIG. 15 , a block-shaped temperature regulation pipe 37 for controlling the temperature of the filaments F was installed upstream of the spinning tube 20 , to adjust the temperature TH of the temperature regulation section in the temperature regulation passage 35 a at 250° C.
  • the cross sectional form of the temperature regulation passage 35 a of the temperature regulation pipe 37 was rectangular, and the length LH of the temperature regulation section as the length of the temperature regulation pipe 37 in the running direction of the filaments F was 60 mm.
  • Ceramic heaters were installed as heating members 36 in the long side direction 37 a of the rectangular temperature regulation passage 35 a . The yarn production conditions and the properties of the obtained yarns in these examples are shown together in Table 10 given later.
  • the swing of the running 36 filaments F in the positions upstream and downstream of the spinning tube 20 was small, and a good spinning state was observed. It was confirmed that the 36 filaments F maintained the disposal of the filaments as achieved immediately after having been discharged from the spinneret 12 , in the range from the upstream side of the spinning tube 20 to the outlet of the spinning tube 20 , and that the filaments F passed through the spinning tube 20 without being converged (without contacting each other).
  • Example 12 The yarn properties of the wound yarns Y were evaluated. Those of Example 12 with the running air stream velocity Ve set at 4,250 m/min were 153% in elongation E, 2.2 g/dtex in strength T and 0.95 in yarn irregularity U%. Compared with Example 1, the winding speed was equal, but a yarn having a higher elongation could be obtained.
  • Example 13 with the running air stream velocity set at 3,200 m/min were 140% in elongation E, 2.4 g/dtex in strength T and 0.92 in yarn irregularity U%. Even if the injection flow rate Ef was lowered, a yarn with the same quality as that of Example 1 could be obtained since the temperature regulation means 35 was used.
  • Example 12 the temperature Ti of the filaments F in the position upstream of the spinning tube 20 was measured and found to be 227° C.
  • the temperature Ti in Example 1 was 215° C. as shown in Table 2, and this value was lower than those of Examples 12 and 13. This means that if the temperature of the filaments F before they enter the spinning tube 20 is kept at a high temperature, an equivalent elongation E can be obtained even if the running air stream velocity Ve in the spinning tube 20 is lowered. Therefore, since the injection flow rate Ef can be decreased, the yarn production cost can be reduced.
  • the apparatus used in Comparative Example 5 was the same as the apparatus shown in FIG. 1 used in Comparative Example 1, except that a cylindrical air stream forming section 70 consisting of a cylindrical cooling means 55 , a funnel-shaped acceleration section 72 and a tube 73 shown in FIG. 3 was installed instead of the cooling means 3 , in which the cooling air 55 a was sent to the tube 73 for generating a parallel stream 73 a in parallel to the running direction of the filaments F in the tube 73 .
  • the cylindrical air stream forming section 70 had the following dimensions: the distance LD from the spinneret 1 to the cylindrical cooling means 55 (spinneret depth) was 25 mm; the length LP of the cylindrical cooling means 55 in the vertical direction (cooling cylinder length) was 300 mm; the angle of the funnel-shaped acceleration section 74 (acceleration taper angle) was 60°; the length LR of the funnel-shaped acceleration section in the vertical direction (acceleration length) was 55 mm; the length LN of the tube 73 (tube length) was 450 mm; and the tube diameter d 1 was 25 mm.
  • the apparatus was the same as that of Comparative Example 1, except the cylindrical air stream forming section 70 .
  • This apparatus was used to produce a polyester yarn consisting of 36 filaments F with a filament fineness D of 135 dtex under the conditions shown in Table 11 given later.
  • the cooling air was supplied to the cylindrical cooling means 55 to achieve a cooling air velocity Vc of 30 m/min, and in this case, it was confirmed that the air velocity Vt in the tube 73 was 2,200 m/min.
  • the yarn production conditions and the properties of the obtained yarn in Comparative Example 5 are shown together in Table 11 given later.
  • the yarn properties of the wound yarn of Comparative Example 5 were evaluated and found to be 108% in elongation E, 2.9 g/dtex in strength T and 1.22 in yarn irregularity U%.
  • the yarn produced in Comparative Example 5 was larger in the value of yarn irregularity U% than in the examples in conformity with the invention, though it could be improved in the value of elongation E.
  • the yarn production apparatus used in Comparative Example 5 was found to be likely to cause yarn irregularity.
  • the apparatus shown in FIG. 19 was used to produce a polyester yarn for evaluation.
  • the yarn production conditions are shown in Table 12 given later.
  • the yarn production state was evaluated for 36 hours after start of yarn production. During this period, the running state of the filaments F was observed adequately, and the produced yarn was sampled every 12 hours, for evaluating the yarn properties.
  • the production of the yarn was stopped 36 hours after start of production. When the production of the yarn was stopped, the state of the filament passage 25 in the spinning tube 20 was observed.
  • the spinning tube 20 used in Example 14 is shown in FIGS. 6 and 7 .
  • the cross sectional form of the filament passage 25 was rectangular.
  • the air inlet section 22 had a widened portion 22 a .
  • the air discharge section 24 had a widened portion 24 a .
  • the length Ex of the short sides of the rectangle as the cross sectional form of the filament passage 25 in the steady flow section 21 was 2 mm, and the length Ey of the long sides was 100 mm.
  • the injection holes 23 a open on the wall faces of the filament passage 25 were formed as slits.
  • the slits were open over the entire length of the long sides 21 L of the rectangle as the cross sectional form of the filament passage 25 .
  • the slit width Ei (see FIG. 9 ) of the slits was 0.4 mm.
  • the correlation between the values indicated by the pressure gauge 67 and the achieved gas velocities was measured beforehand, to obtain the value of the suction gas velocity SV.
  • the numerous filaments F were guided to run downward at the center between the gas suction ports 62 installed on both sides of the filaments.
  • the distance between each gas suction port 62 and the filaments F was set at 1 ⁇ 2 of the distance between both the gas suction ports 62 .
  • honeycomb grate members (thickness 15 mm, grate pitch 3 mm) were used and installed on both sides of the numerous filaments F in parallel with them.
  • side plates 68 were used to close the faces in the short side direction against the outside (see FIG. 22 ).
  • SL (mm) indicates the distance from the bottom face of the spinneret 12 to the top face of the gas suction device 60 , and defines the space below the nozzle.
  • BL (mm) indicates the length of the gas suction device 60 in the vertical direction, and defines the suction region.
  • AL (mm) indicates the length of the suction spaces 80 (see FIG. 23 ) from the bottom face of the gas suction device 60 to the top face of the spinning tube 20 in the vertical direction, and defines the ventilation distance.
  • L 1 (mm) indicates the distance from the bottom face of the spinneret 12 to the top face of the spinning tube 20 , and defines the spinning tube position.
  • L 2 (mm) indicates the overall length of the spinning tube 20 and defines the spinning tube length.
  • L 3 (mm) indicates the distance from the bottom face of the spinneret 12 to the oiling means 17 and defines the oiling position.
  • L 4 (mm) indicates the distance from the bottom face of the spinneret to the first godet roller 14 , and defines the take-up position.
  • Vw (m/min) indicates the yarn Y take-up speed by the first godet roller 14 , and defines the take-up speed.
  • Es (mm) indicates the distance from the top face of the spinning tube 20 to the injection holes 23 a of the air injection section 23 (the center of the open faces of the injection holes 23 a in the vertical direction on the wall faces of the filament passage 25 ), and defines the slit position.
  • the distance between the respectively adjacent spinning holes 13 is called the spinning hole pitch P (mm)
  • the hole diameter of the spinning holes 13 on the bottom face of the spinneret 12 is called the spinning hole diameter d (mm).
  • the center distance between the two spinning holes most apart from each other among the plural spinning holes 13 is called the distance dw (mm) between the outermost spinning holes.
  • the apparatus of FIG. 19 was used to produce a polyester yarn (PET yarn) consisting of 36 filaments F with a filament fineness D of 135 dtex under the conditions shown in Table 12 given later at a speed of 5,000 m/min.
  • the spinneret 12 used had all the numerous spinning holes arranged in a straight line Z as shown in FIG. 5A .
  • the spinning hole pitch P was 2.5 mm
  • the spinning hole diameter d was 0.3 mm
  • the distance dw between the outermost spinning holes was 87.5 mm.
  • Example 15 and Comparative Example 6 were carried out under the same conditions, except that the gas suction velocity SV was changed.
  • the yarn properties of the yarns sampled after lapse of predetermined times are shown in Table 13.
  • the evaluated yarn properties were strength T, elongation E, yarn irregularity U% and fluff K.
  • Table 13 also shows the results of the inner face of the filament passage 25 of the spinning tube 20 observed 36 hours after start of yarn production.
  • Example 14 and 15 the swing of filaments F was small throughout the yarn production period, and a good spinning state was maintained. It was confirmed that the numerous filaments F maintained the disposal of the filaments as achieved immediately after having been discharged from the spinneret 12 , in the range from the spinneret 12 to the outlet of the spinning tube 20 , and that the filaments passed through the spinning tube 20 without being converged (without contacting each other). The yarn properties of the wound yarns were evaluated.
  • Example 14 As shown in Table 13, the yarn irregularity U% values in Example 14 were 0.85 after lapse of 12 hours, 0.88 after lapse of 24 hours and 0.84 after lapse of 36 hours, and those in Example 15 were 0.83 after lapse of 12 hours, 0.80 after lapse of 24 hours and 0.82 after lapse of 36 hours. On the whole, the fluff of yarns was not observed. Thirty six hours after start of yarn production, the yarn production was stopped, and the spinning tube 20 was dismantled, to inspect the deposition of the volatile matter onto the filament passage 25 . The deposition of the volatile substance was substantially not observed, and the filament passage was little contaminated and kept in a good state.
  • PET yarns polyethylene terephthalate yarns
  • the polymer used is not especially limited.
  • the yarn production method and apparatus can be especially preferably applied to a polylactic acid yarn, since it generates a large amount of a volatile matter.
  • Example 1 Example 2
  • Example 3 Example 4 Vw: Take-up speed m/min 5,000 ′′ ′′ ′′ D: Fineness dtex 135 ′′ ′′ ′′ ′′ F: Number of filaments Number 36 ′′ ′′ ′′ d: Spinning hole diameter mm 0.3 ′′ ′′ ′′ ′′ P: Spinning hole pitch mm 2.5 ′′ ′′ ′′ L2: Spinning tube length mm 300 ′′ ′′ ′′ Ey: Length of long sides of passage mm 100 ′′ ′′ ′′ Ex: Length of short sides of passage mm 2 ′′ ′′ ′′ ⁇ : Injection angle degrees 15 ′′ ′′ ′′ Ei: Injection slit width mm 0.4 ′′ ′′ ′′ Es: Injection slit position mm 50 ′′ ′′ ′′ L1: Spinning tube position mm 100 200 300 400 L3: Oiling means position mm 1,500 ′′ ′′ ′′ L4: Take-up position mm 3,200 ′′ ′′ ′′ Ef: Injection flow rate m
  • Example 1 Example 2
  • Example 3 Take-up speed mm 700 900 800 reaching position La: Maximum mm 650 550 450 acceleration position
  • Example 5 Com- parative Item Unit
  • Example 5 Example 4 Vw: Take-up speed m/min 5,000 ′′ ′′ D: Fineness dtex 135 ′′ ′′ F: Number of filaments Number 36 ′′ ′′ d: Spinning hole diameter mm 0.3 ′′ ′′ P: Spinning hole pitch mm 2.5 ′′ ′′ L2: Spinning tube length mm 300 ′′ ′′ Ey: Length of long sides mm 100 ′′ ′′ of passage Ex: Length of short sides mm 2 ′′ ′′ of passage ⁇ : Injection angle degrees 15 ′′ ′′ Ei: Injection slit width mm 0.4 ′′ ′′ Es: Injection slit position mm 50 ′′ ′′ L1: Spinning tube position mm 100 ′′ ′′ L3: Oiling means position mm 1,500 ′′ ′′ L4: Take-up position mm 3,200 ′′ ′′ Ef: Injection flow rate m 3 /min 0.5 0.4 0.3 Vs: Injection velocity m/min 6,000 4,900
  • Example 4 Take-up speed mm 900 1,000 1,000 reaching position La: Maximum mm 250 350 650 acceleration position VL: Filament speed m/min 1,800 2,300 3,500 at maximum acceleration position Le: Spinning tube range L1: mm 100 100 100 L1 + L2 mm 400 400 400 400
  • Example 11 Take-up speed m/min 5,000 ′′ D: Fineness dtex 135 ′′ F: Number of filaments Number 36 ′′ d: Spinning hole diameter mm 0.3 ′′ P: Spinning hole pitch mm 2.5 ′′ Lc: Air regulation plate length mm — 60 Lt: Air regulation plate thickness mm — 10 L2: Spinning tube length mm 300 ′′ Ey: Length of long sides mm 100 ′′ of passage Ex: Length of short sides mm 2 ′′ of passage ⁇ : Injection angle degrees 15 ′′ Ei: Injection slit width mm 0.4 ′′ Es: Injection slit position mm 50 ′′ L1: Spinning tube position mm 100 ′′ L3: Oiling means position mm 1,500 ′′ L4: Take-up position mm 3,200 ′′ Ef: Injection flow rate m 3 /min 0.5 ′′ Vs: Injection velocity m/min 6,000 ′′ Ve: Running air stream m/min 4,250 .
  • Example Example Item Unit Example 1 12 13 Vw: Take-up speed m/min 5,000 ′′ ′′ D: Fineness dtex 135 ′′ ′′ F: Number of filaments Number 36 ′′ ′′ d: Spinning hole diameter mm 0.3 ′′ ′′ P: Spinning hole pitch mm 2.5 ′′ ′′ LH: Temperature mm — 60 60 regulation section length TH: Temperature ° C.
  • the yarn production method and apparatus of the invention use a spinneret having numerous spinning holes arranged at a desired pitch as a row or plural rows in a straight line(s), a spinning tube (ejector) having a filament passage through which a row(s) of numerous filaments composed of a polymer discharged from the spinning holes and running downward from the spinneret pass (es), an oiling means for applying an oiling agent to the numerous filaments coming out of the spinning tube, a take-up means for taking up the oiled numerous filaments, and a yarn winding means for winding the numerous filaments coming from the take-up means, wherein in the filament passage of the spinning tube, air is injected obliquely downward toward the numerous filaments disposed in the row direction of the spinning holes and entering the filament passage, from both sides of the disposal of the numerous filaments, to dispose the numerous filaments in one row without allowing them to overlap each other, and the air stream formed as a confluence of the air streams injected obliquely downward from both sides and running
  • the obtained yarn is small in the irregularity between filaments. Even in the case where the width of the filament passage in the direction perpendicular to the direction in which the numerous filaments are disposed side by side is small, since the gas generated from the numerous filaments in the range between the spinneret and the spinning tube is sucked and discharged outside, it can be prevented that the volatile substance of the filaments contaminates the filament passage having a narrow width. So, a stable yarn can be continuously produced without suspension of yarn production.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
US10/516,835 2002-06-03 2003-05-28 Device and method for manufacturing thread line Abandoned US20060145385A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
JP2002-161124 2002-06-03
JP2002161124 2002-06-03
JP2003-73260 2003-03-18
JP2003073260 2003-03-18
PCT/JP2003/006653 WO2003102278A1 (fr) 2002-06-03 2003-05-28 Dispositif et procede de fabrication de fil

Publications (1)

Publication Number Publication Date
US20060145385A1 true US20060145385A1 (en) 2006-07-06

Family

ID=29714323

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/516,835 Abandoned US20060145385A1 (en) 2002-06-03 2003-05-28 Device and method for manufacturing thread line

Country Status (5)

Country Link
US (1) US20060145385A1 (zh)
EP (1) EP1510603A4 (zh)
CN (1) CN1659319A (zh)
TW (1) TW200307771A (zh)
WO (1) WO2003102278A1 (zh)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090256278A1 (en) * 2006-11-10 2009-10-15 Oerlikon Textile Gmbh & Co. Kg Process and device for melt-spinning and cooling synthetic filaments
US20150042004A1 (en) * 2012-03-14 2015-02-12 Mitsubishi Rayon Co., Ltd. Device for producing hollow porous film and method for producing hollow porous film
JP2015028228A (ja) * 2012-10-22 2015-02-12 株式会社リメディオ 乾式紡糸装置、不織布製造装置、および紡糸方法
EP3147392A1 (en) * 2015-09-16 2017-03-29 TMT Machinery, Inc. Melt spinning device
CN106637444A (zh) * 2016-12-02 2017-05-10 宁波大发化纤有限公司 一种丝束自动喷油剂装置
CN107012515A (zh) * 2016-01-27 2017-08-04 赖芬豪泽机械工厂有限及两合有限公司 用于由连续长丝制造纺粘型非织造织物的设备和方法
US20180112333A1 (en) * 2015-04-25 2018-04-26 Oerlikon Textile Gmbh & Co. Kg Process and device for the melt spinning and cooling of multifilament threads
CN111826729A (zh) * 2019-04-23 2020-10-27 日本Tmt机械株式会社 熔融纺丝设备
EP4411035A1 (en) * 2023-01-26 2024-08-07 TMT Machinery, Inc. Yarn production system
EP4411034A1 (en) * 2023-01-26 2024-08-07 TMT Machinery, Inc. Yarn production system

Families Citing this family (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2012203471B2 (en) * 2005-01-28 2013-10-31 Mmr Marketing & Management Ag Rotkreuz Extruder system for extruding a fluid
EP1841904A1 (de) 2005-01-28 2007-10-10 MMR Marketing & Management AG Rotkreuz Extrudersystem zum strangformen eines fluids
DE102008029550A1 (de) * 2008-06-21 2009-12-24 Oerlikon Textile Gmbh & Co. Kg Vorrichtung zum Abziehen von Filamenten
CN102199796B (zh) * 2011-06-14 2012-08-08 大连合成纤维研究设计院股份有限公司 可调式环吹风冷却系统
CN103774248B (zh) * 2011-10-09 2017-01-25 青岛中韩联谊新材料技术有限公司 导热效率较高且适于大幅节能的纺丝箱用节能式纺丝模头
JP2015014071A (ja) * 2013-07-08 2015-01-22 Ｔｍｔマシナリー株式会社 糸条冷却装置
CN106637443B (zh) * 2017-02-22 2020-04-14 天鼎丰聚丙烯材料技术有限公司 侧吹风装置和纺丝机
CN107201559B (zh) * 2017-07-17 2023-04-25 吉林农业大学 一种珠头喷头静电纺丝装置
JP6965922B2 (ja) * 2018-03-29 2021-11-10 東レ株式会社 延伸装置、ならびに、繊維および繊維ウェブの製造装置および製造方法
DK3575470T3 (da) * 2018-05-28 2020-12-14 Reifenhaeuser Masch Indretning til fremstilling af filterdug af endeløse filamenter
CN109056084B (zh) * 2018-07-09 2020-08-18 山东惠民展鹏网业有限公司 一种用于化纤生产过程中的冷却装置
DE102018008602A1 (de) * 2018-10-31 2020-04-30 Oerlikon Textile Gmbh & Co. Kg Vorrichtung zum Abziehen und Aufwickeln einer schmelzgesponnenen Fadenschar
CN112111798A (zh) * 2020-09-29 2020-12-22 广东新会美达锦纶股份有限公司 一种聚酰胺6色母粒的对色装置
DE102021000149A1 (de) 2021-01-15 2022-07-21 Oerlikon Textile Gmbh & Co. Kg Vorrichtung zum Schmelzspinnen und Abkühlen einer frisch extrudierten Filamentschar

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5824248A (en) * 1996-10-16 1998-10-20 E. I. Du Pont De Nemours And Company Spinning polymeric filaments
US5976431A (en) * 1993-12-03 1999-11-02 Ronald Mears Melt spinning process to produce filaments

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5347411B2 (zh) * 1974-05-14 1978-12-21
US5034182A (en) * 1986-04-30 1991-07-23 E. I. Du Pont De Nemours And Company Melt spinning process for polymeric filaments
TW561204B (en) * 2000-03-24 2003-11-11 Toray Eng Co Ltd Molten yarn take-up device
CN1446274A (zh) * 2000-07-10 2003-10-01 纳幕尔杜邦公司 生产聚合物长丝的方法

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5976431A (en) * 1993-12-03 1999-11-02 Ronald Mears Melt spinning process to produce filaments
US5824248A (en) * 1996-10-16 1998-10-20 E. I. Du Pont De Nemours And Company Spinning polymeric filaments

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090256278A1 (en) * 2006-11-10 2009-10-15 Oerlikon Textile Gmbh & Co. Kg Process and device for melt-spinning and cooling synthetic filaments
US8178015B2 (en) * 2006-11-10 2012-05-15 Oerlikon Textile Gmbh & Co. Kg Process and device for melt-spinning and cooling synthetic filaments
US20150042004A1 (en) * 2012-03-14 2015-02-12 Mitsubishi Rayon Co., Ltd. Device for producing hollow porous film and method for producing hollow porous film
JP2015028228A (ja) * 2012-10-22 2015-02-12 株式会社リメディオ 乾式紡糸装置、不織布製造装置、および紡糸方法
US10801130B2 (en) * 2015-04-25 2020-10-13 Oerlikon Textile Gmbh & Co. Kg Process and device for the melt spinning and cooling of multifilament threads
US20180112333A1 (en) * 2015-04-25 2018-04-26 Oerlikon Textile Gmbh & Co. Kg Process and device for the melt spinning and cooling of multifilament threads
EP3147392A1 (en) * 2015-09-16 2017-03-29 TMT Machinery, Inc. Melt spinning device
CN107012515A (zh) * 2016-01-27 2017-08-04 赖芬豪泽机械工厂有限及两合有限公司 用于由连续长丝制造纺粘型非织造织物的设备和方法
US10465319B2 (en) 2016-01-27 2019-11-05 Reifenhaeuser Gmbh & Co. Kg Maschinenfabrik Method and apparatus for making a spunbond nonwoven from endless filaments
CN106637444A (zh) * 2016-12-02 2017-05-10 宁波大发化纤有限公司 一种丝束自动喷油剂装置
CN111826729A (zh) * 2019-04-23 2020-10-27 日本Tmt机械株式会社 熔融纺丝设备
EP3730678A1 (en) * 2019-04-23 2020-10-28 TMT Machinery, Inc. Melt spinning system
EP4411035A1 (en) * 2023-01-26 2024-08-07 TMT Machinery, Inc. Yarn production system
EP4411034A1 (en) * 2023-01-26 2024-08-07 TMT Machinery, Inc. Yarn production system

Also Published As

Publication number Publication date
CN1659319A (zh) 2005-08-24
TW200307771A (en) 2003-12-16
WO2003102278A1 (fr) 2003-12-11
EP1510603A4 (en) 2006-12-13
EP1510603A1 (en) 2005-03-02

Similar Documents

Publication Publication Date Title
US20060145385A1 (en) Device and method for manufacturing thread line
US6800226B1 (en) Method and device for the production of an essentially continous fine thread
US6551545B1 (en) Method and apparatus for melt spinning a multifilament yarn
US4863662A (en) Method for melt-spinning thermoplastic polymer fibers
US5439364A (en) Apparatus for delivering and depositing continuous filaments by means of aerodynamic forces
EP0034880B1 (en) Process for forming a continuous filament yarn from a melt spinnable polyethylene terephthalat and novel polyester yarns produced by the process
CN110541241B (zh) 用于由连续长丝制造纺粘型非织造织物的设备和方法
TW200301788A (en) Spinning apparatus and method with blowing by means of a turbulent cooling gas stream
KR100389668B1 (ko) 중합체 필라멘트의 방사 공정
US6705852B2 (en) Melt spinning apparatus
US4492557A (en) Filament quenching apparatus
JPH02104710A (ja) フィラメントの改善された凝固法
JP2000503076A (ja) 溶融紡糸されたモノフイラメントを製造する方法及び装置
EP1629141B1 (en) Apparatus and method for controlling airflow in a fiber extrusion system
US5360589A (en) Process for producing synthetic filaments
US20210292950A1 (en) Making spunbond from continuous filaments
JPH07501365A (ja) 合成無端フィラメントの製造方法及び装置
JP2011102448A (ja) フィラメント糸の製造装置および製造方法
KR20050016507A (ko) 사조 제조 방법 및 장치
JP2004060137A (ja) 糸条の製造方法および装置
JP2002038328A (ja) 溶融紡糸装置
WO2019187887A1 (ja) 延伸装置、ならびに、繊維および繊維ウェブの製造装置および製造方法
JPS6128012A (ja) 異形断面繊維の溶融紡糸方法
CN113622034B (zh) 利用受控气流的长丝的生产
JPH07109614A (ja) 極細マルチフィラメント糸の溶融紡糸方法及びその装置

Legal Events

Date Code Title Description
AS Assignment

Owner name: TORAY INDUSTRIES, INC., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FUJII, TAKASHI;SANO, TAKAO;FURUTA, HIROKI;AND OTHERS;REEL/FRAME:016697/0887;SIGNING DATES FROM 20041028 TO 20041113

STCB Information on status: application discontinuation

Free format text: EXPRESSLY ABANDONED -- DURING EXAMINATION