US3347727A - Textured filament yarns - Google Patents

Textured filament yarns Download PDF

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Publication number
US3347727A
US3347727A US283389A US28338963A US3347727A US 3347727 A US3347727 A US 3347727A US 283389 A US283389 A US 283389A US 28338963 A US28338963 A US 28338963A US 3347727 A US3347727 A US 3347727A
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United States
Prior art keywords
resin
fibers
yarn
layer
yarns
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US283389A
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Bobkowicz Emilian
Bobkowicz Andrew John
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
    • D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
    • Y10T156/1087—Continuous longitudinal slitting

Definitions

  • the present invention relates to a method for making yarn from staple fibers without the necessity for any roving or drafting operations of the type utilised in conventional yarn making methods.
  • the method of the present invention does not depend only on the cohesion forces between the fibers but relies on adhesion forces derived from a resinous bonding agent introduced for the purpose of adhering the fibers to one another to form a yarn having a permanent twist.
  • the method of the invention eliminates in most cases the drawing and in all cases the complex and necessary slow roving and drafting stages of the conventional method; this makes feasible much higher yarn making speeds as well as automation of the entire processing of staple fibers in one continuous sequence of steps from ber webs to yarn.
  • the present invention affords filament yarns which have advantages over known types of filament yarn.
  • filament is defined as an individual strand that is infinite in length. Man-made filaments are infinite in length and may attain a total length of several miles.
  • a filament yarn may comprise mono or multifilaments without or with twist, which when present is usually slight.
  • a textured filament yarn is a generic term for any filament yarn modified in such a way that its original physical and surface properties have been changed. The term implies that a dierent texture has been imposed on the extruded shape of the filament.
  • All three methods are variations of a single technique using a spinneret which has many fine holes through Which a man-made liquid substance is forced and right after extrusion is solidified into continuous multior mono-filaments, the yarns of which are straight and due to the extrusion technique have a highly smooth surface and shape.
  • the filaments are either chopped or broken up into staple fibers corresponding to natural fiber length, so that the staple fibers obtained of the filaments can .again be processed on existing conventional machinery and by the complex and costly conventional y-arn making methods into continuous yarns and textures similar to the conventional yarns made of natural fibers. To further neutralize previously said disadvantagesof man-made fibers they are often blended with various natural fibers.
  • textured yarns are either crimped, coiled, curled, or looped.
  • the usual process of texturizing of filaments comprises continuous high speed operations the costs involved considerably increase the price of the final product, the textured yarn, because it has to pass through five phases of processing, as is for instance the case in the production of nylon textured yarns, as follows:
  • Phase oma The filament yarn has to be removed from the bobbin Phase two.-The individual filaments of the yarn are displaced from their natural and relatively close packed position either by mechanical ⁇ distortion (for example twisting) or by other means.
  • Phase three.* The displaced filaments comprising the yarn are made to assume a permanent configuration, as by heat-setting Phase fama-The forces which caused the filament displacement in phase two are removed (by untwisting, if the filaments have been displaced by twisting) so that the yarns assume permanent bulk and/or stretch characteristics, particularly after relaxation.
  • Phase five-In this phase the textured yarn is Wound into a suitable package.
  • textured yarns thus involves the making of a filament, then its reprocessing on complex and costly machines into textured filament yarns by passing through the above five stages of processing. For these reasons textured filament yarns are among the most expensive yarns on the market. Staple fiber yarns'made from man-made fibers (or their blends with natural fibers) necessitate also first of all, the making of a filament, which after processing into staple fibers and blending with other fibers must pass through many costly stages of 3 conventional staple yarn production, ⁇ such as opening, blending, picking, carding, drafting, roving, twisting and winding before the final yarn evolves. In both cases, thus, the production involves two distinct, different, separate and discontinuous stages of processing and different equipment.
  • the present invention makes feasible the production of acornposite lament yarn with a texture which will eliminate all the disadvantages previously mentioned of a conventional smooth and straight filament yarn in which yarn, if and when desired or preferred, any positive normal or heat-set twist of heat-setfalse twist can be imparted to increase its textured and/ or stretch yarn character.
  • textured filament yarns can be produced from any extrudable thermoplastic materials such a nylon, polypropylene, acrylonitrile, polyethylene, rubber compounds, etc.
  • thermosetting agents any type of short or long staple lfibers in loose or preformedfiber webs, of random or parallel arranged fibers or in the form of pulp, paper, etc., in one continuous sequence of operations from a suitable raw material to ready filament yarn package.
  • the apparatus illustrated includes an extruder 1 comprising a hopper 2, and a heating charnber 3. Synthetic resin is fed into the hopper ⁇ 2, from which it passes into the heating chamber 3 to be melted. The molten resin passes through a connection 4 to an extrusion head 5 from which the resin is extruded in the form ⁇ of a layer l6 consisting of a continuous still plastic film or a plurality of continuous larnents parallel with one another.
  • a carding or garnetting or other device 7 well known in the art for producing an aligned fiber web.
  • the devices 7 are utilized for the purpose of forming fibrous webs 8 and 9 from staple fibers, each of the webs having the fibers v thereof substantially arranged parallel to the longitudinal extent of the web.
  • the webs 8 and 9 are fed by Way of guide rolls 10 and 11 towards opposite sides ⁇ of the resinous layer 6. ⁇ The sandwich thereby formed from the resinous layer 6 and the webs 8 and 9-is then fed between a pair of cooled rolls 12 which are ⁇ driven at such a speed that they take up the layer 6 at a greater rate than it is extrudedffrom the head 5, thereby maintaining the layer 6 under tension.
  • the cooled rolls 12 serve other purposes. In the first place they exert pressure which causes flow of the resinous material into the webs 8 and 9. In kthe second place they exertr a cooling action on the resinous material which causes it to coagulate. The net effect is to produce a composite web 13 wherein the fibers of the webs 8 and 9 are securely bonded to the resinous layer 6 at the points of contact with same.
  • the composite web 13 is passed around a guide 14 and fed to a slitter device 1S where it is slit into a plurality of ribbons 16.
  • the ribbons 16 are fed to a twisting machine 17 comprising a plurality of spindles 18 which need not be described in detail because they arek of the kind described and illustrated in our U.S. Patent No. 2,900,782 issued on Aug. 25, 1959.
  • the spindles 18 deposit packages 19 in pots 20. If desired the spindles 18 could be replaced by conventional ring spindles.
  • the spacing between the cooled rolls 12 is as adjusted as to exert a firm gripping pressure on the sandwich of the webs 8 and 9 and the resinous layer 6 and the rate of extrusion from the extrusion head 5 so controlled as to keep therresinous layer.6 under tension.
  • This ⁇ arrange- ⁇ 4 ment provides a means of controlling the thickness of the resinous layer 6 and khence the ratio of resin to fiber in the final product.
  • the tension on the resinous layer 6 is sufiicient to ensure a desirable stretching action so that by the time the resinous layer 6 reaches the nip of the rolls 12 ⁇ orientation of the resin moleculesin the hot ⁇ sheet has been effected.
  • films or filaments of many syntheticvresins can be considerably strengthened if they are subjected to stretching action great enough to causeiorientation of the resin molecules in the direction of the longitudinal extent of the film or filament- This increase of strength is accompanied by an increase in length of the film or filament. Therefore, the resinous layer 6 which is delivered to the nip ofthe cooled roll 12 has considerable strength due to thestretching which has been exerted on it.
  • the cooling action exerted on the resinous layer ⁇ 6 by the rolls 12 serves to set the molecules of the resinous'layer 6 in their oriented positions so that the composite web 13 is bonded together by a resinous layer of considerable strength.
  • the webs 8 and 9 contacted the layer 6 at a distance of about 3 inches below the head 5 where the temperature of the layer 6 haddropped to about 350 to 400 F.
  • the rate of extrusion of the resin from the head S was such as to give the layer ⁇ 6 a linear speed of about 10 feet per minute while the rolls 12 were rotated at such'a speed as to take up to layer ⁇ 6 at about 100 feet per minute, thereby exerting tension on the layer 6 between the head 5 and the rolls '12.
  • the composite web 13 obtained in ⁇ this way was split 1nto ribbons and the ribbons were twisted into yarns.
  • Another advantage of the method of the present invention by comparison with a generally similar technique in which a prefabricated film or filament is used instead of a directly extruded material is that the nature of the resin can be readily adjusted to meet the prevailing requirements.
  • Commercially available films and filaments contain in many cases ingredients which are important for one reason or another in the products which are to be used in that form. Such ingredients include for example delustering agents, components having an affinity for dyestufrs and so on. Such materials are of no particular value when forming a resin-bonded yarn and may even be deleterious.
  • the resin used for bonding the fibers together can withoutV any difficulty be given a composition which is thought to be most appropriate for the particular material being produced. Unnecessary ingredients can be left out.
  • thermosetting resin in the resinous mixture offers no difficulty. Indeed it is possible to utilize a resin mixture consisting entirely of a thermosetting resin. Films and filaments of thermosetting resins such as phenol formaldehyde resins and urea formaldehyde resins are not commercially available. The addition of such resins may be desired for the purpose of increasing the strength and stiffness of the resin-bonded fibrous product. Furthermore, it may be desir-able to operate with a higher content of plasticizer than is commonly used in films or filaments. This can be achieved without difficulty in the method of the present invention.
  • Another important advantage in the method of the invention is that use can be made of resins or resin mixtures which have a high melting point without impairing the qualities of the fibers in the fibrous webs. At the moment that the resin comes into contact with the fibrous webs the sandwich thereby formed is immediately subjected to the cooling action of the rolls 12. The fibers in the webs 8 and 9 are therefore not subjected to temperatures which could impair their properties. In a method where the directly extruded resinous layer 6 is replaced by a layer of prefabricated films or filaments and the coolings rolls 12 replaced by heated rolls damaging of the fibers in the webs is likely to occur if the resinous material involved has a high melting point.
  • degradation of the fibers can occur, if at all, only at the parts of the fibrous web immediately adjacent the fibrous layer, the bulk of the web being maintained at a lower temperature due to the action of the cooled rolls 12. Because of this feature of the invention of achieving satisfactory bonding between the fibers and the resinous material without exposing the fibers to unduly high temperatures it is possible to make resin bonded fibrous products from combinations of fibers and resins that could not be successfully treated if the resins were supplied in the form of a prefabricated :film or filament.
  • the process illustrated in the drawing can be modified in many ways within the scope of the invention.
  • the process of the invention essentially comprises forming a directly extruded layer of a resinous material and a fibrous web in which the fibers have preferably been brought into substantially parallel relationship with one another in the longitudinal extent of the web, bringing the resinous layer and the fibrous web together, subjecting them to cooling and pressure to form a composite web in which the fibers are bonded to one another by means of the resinous material.
  • two identical fibrous webs may be used to form the composite web as illustrated in the accompanying drawing. However, a single fibrous web is sufficient.
  • one of the fibrous webs 8 and 9 could be replaced by a layer of paper or pulp or metallic foil.
  • the production of yarns from such a web could be effected by twisting the ribbons cut from the web in such a manner as to dispose the paper or pulp in the interior of the yarn. In this manner there can be economically produced a bulky yarn. Similar results could be achieved by using in place of paper or pulp a randomly arranged fibrous web, for example, a web of linters. Also, both of the fibrous 'webs 8 and 9 could be replaced by paper or paper pulp.
  • the invention is primarly concerned with the production of resin-bonded yarn.
  • the composite webs produced according to the invention are useful in themselves as wrapping and covering materials. In particular, they can be used as imitation leather.
  • the bonding of the fibrous webs together can be achieved by means of a resinous layer which may be a continuous film or may be made up of a plurality of continuous filaments.
  • the nature of the resin employed is not critical.
  • the resin may be a polyamide, polyacrylate, la cellulose ester, especially cellulose acetate, a regenerated cellulose, polyethylene, polypropylene, a polyester and so on.
  • thermostatting resins may be used if desired.
  • the fibers from which the fibrous webs are made are also capable of much Variation.
  • the fibers may be animal fibers, such as wool; vegetable fibers such as cotton; bast fibers such as ramie, jute flax, hemp or kenaf; hard fibers such as sisal, sansiveria or agave; glass fibers; mineral fibers such as asbestos; and man-made fibers such as polyamide, polyester, polyacrylonitrile and so on.
  • the fibers may be dispersed in an air current and blown on to the tacky surface of the resin ⁇ layer by suitable blower meansso that a web of the fibers is formed on ⁇ the surface of the resin layer.
  • the method of the invention makes possiblethe production of yarns which possesses the strength of a conventional filament yarn in that they have ⁇ a continuous core of synthetic resin and at the same time have the ⁇ surface characteristics of a textured yarn due to the presence of an outer sheath of staple fibers. This is in contrast to yarns produced by impregnatin'g staple fibers with resin; in such yarns the resin is diffused through the fiber mass so that a harder yarnis obtained. Also, the yarns of the present invention can readily be produced with a high degree of evenness whereas withyarns produced by conven-l tional textile methods this is more difficult since each of the series of steps involved in a conventional method of yarn production is capable of, causing unevenness in the yarn.
  • the method of the invention thus yields novel yarns comprising a continuous core of a resin and fibrous material anchored to said core in that portions of the fibrous material are embedded in said corewhile other portions of the brous material, which are substantially free from said resin, extend from the core to provide a sheath hav ing the normal surface characteristics of said fibrous material.
  • the anchoring of the fibrous material to the core is enhanced by the imparting of a twist to the yarn which gives said core a helical form and serves to trap portions of the resin-free fiber between adjacent coils of ⁇ the helical core thus formed.
  • a continuous method of making textured filament yarn comprising: extruding a soft layer of resin through an extrusion head; stretching said layer of resinv in the longitudinal direction to cause orientation of the resin molecules; contacting said soft layer of resin, on atleast one side thereof, with a fibrous material, compressing said resin and fibrous material together with cooling thereby forming a composite web; dividing said composite web longitudinally into a plurality of ribbons of predetermined width; and transforming said ribbons into yarns by means of a twisting operation.
  • said fibrous material is a web of staple fibers arranged substantially according to claim 1, wherein ⁇ the pressing effected by passing said soft layer of resin in contact with said material through thev nip of a pair of cooled rolls.
  • said soft layer of resin is a web composed of a plurality of continuous parallel filaments.
  • a method ⁇ according to is a thermoplastic resin selected from the group consisting of nylon, polypropylene, acrylonitrile, polyethylene and rubber compounds.
  • thermoplastic resin is blended with a thermosetting resin selected from the group consisting of phenol-formaldehyde resins and urea-formaldehyde resins.
  • material is paper fiber.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US283389A 1962-05-29 1963-05-27 Textured filament yarns Expired - Lifetime US3347727A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB20617/62A GB1000998A (en) 1962-05-29 1962-05-29 Textured filament yarns

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US3347727A true US3347727A (en) 1967-10-17

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US283389A Expired - Lifetime US3347727A (en) 1962-05-29 1963-05-27 Textured filament yarns
US662220A Expired - Lifetime US3481132A (en) 1962-05-29 1967-06-09 Textured filament yarns

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US662220A Expired - Lifetime US3481132A (en) 1962-05-29 1967-06-09 Textured filament yarns

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US (2) US3347727A (fr)
BR (1) BR7018045D0 (fr)
CH (2) CH405123A (fr)
ES (1) ES288492A1 (fr)
GB (1) GB1000998A (fr)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3449187A (en) * 1964-12-08 1969-06-10 Bobkowicz E Method and apparatus for making nonwoven fabrics
US3540963A (en) * 1964-05-18 1970-11-17 Johnson & Johnson Method of making a composite absorbent laminate
DE2312816A1 (de) * 1973-03-15 1975-02-06 Basf Ag Verfahren zur herstellung von halbzeug aus faserverstaerkten thermoplastischen kunststoffen
US3939873A (en) * 1973-08-27 1976-02-24 Exxon Research And Engineering Company Corrosion resistant glass-reinforced plastic pipe liner
US3959059A (en) * 1968-02-16 1976-05-25 Leon Rollin Alexander Method and apparatus for flocking continuous webs
US3968283A (en) * 1974-05-21 1976-07-06 Scott Paper Company Flocked filamentary element and structures made therefrom
US3983202A (en) * 1969-06-26 1976-09-28 Shell Oil Company Manufacture of synthetic fibers and yarns
US4623579A (en) * 1983-10-04 1986-11-18 Multi-Tex Products Corp. Yarn product with combined fluorescent-phosphorescent appearance and method
US20030096901A1 (en) * 2000-04-13 2003-05-22 Jari Aarila Polymer composition for pipes
US6968866B2 (en) * 2000-10-10 2005-11-29 Taiyo Kogyo Corporation Tent fabric, twisted union yarn of kenaf, and process for producing the same
US20100000195A1 (en) * 2008-07-02 2010-01-07 AG Technologies, Inc. Process for manufacturing yarn made from a blend of polyester fibers and silver fibers
US20100000196A1 (en) * 2008-07-02 2010-01-07 AG Technologies, Inc. Process for manufacturing yarn made from a blend of fibers of cotton, nylon and silver
CN115354427A (zh) * 2022-01-20 2022-11-18 浙江理工大学 一种复合纸纱的制备装置及其制备方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4428752A (en) 1982-07-22 1984-01-31 Bertrand Goldenstein High bulk olefin blended yarn

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2684319A (en) * 1944-03-31 1954-07-20 Orlan M Arnold Method of making fabric
US2714571A (en) * 1952-04-08 1955-08-02 Dobeckmun Co Process for bonding a polyethylene film to a fibrous web
US3012393A (en) * 1960-11-21 1961-12-12 Mohasco Ind Inc Method and apparatus for the production of paper yarn
US3161560A (en) * 1961-01-04 1964-12-15 Int Paper Co Extrusion coated paper and method of making the same
US3219507A (en) * 1961-02-20 1965-11-23 Magee Carpet Co Method of applying plastic sheet to pile fabric backing

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA595309A (en) * 1960-03-29 E. Weiss Eric Composite yarns and fabrics and method of making same
GB552130A (en) * 1941-04-02 1943-03-24 British Celanese Improvements in or relating to the production of composite yarns, cords, braids, fabrics and similar textile products
US2306781A (en) * 1941-07-17 1942-12-29 Sylvania Ind Corp Product containing siliceous fibers and method of making the same
US2526523A (en) * 1946-03-07 1950-10-17 United Merchants & Mfg Yarn and fabric and method of making same
US2483861A (en) * 1947-11-12 1949-10-04 United Merchants & Mfg Textile materials and method of making same
US2506667A (en) * 1948-11-24 1950-05-09 Edward H Hall Composite textile yarn for use in papermaking felts
US2743573A (en) * 1951-09-11 1956-05-01 Textile Machinery Corp Methods of production of textile yarns
US2795926A (en) * 1954-02-23 1957-06-18 Owens Corning Fiberglass Corp Method for producing a continuous roving
US3205648A (en) * 1962-10-22 1965-09-14 James L Lohrke Novelty yarn
US3382662A (en) * 1965-07-15 1968-05-14 Wyomissing Corp Covered elastomeric yarns

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2684319A (en) * 1944-03-31 1954-07-20 Orlan M Arnold Method of making fabric
US2714571A (en) * 1952-04-08 1955-08-02 Dobeckmun Co Process for bonding a polyethylene film to a fibrous web
US3012393A (en) * 1960-11-21 1961-12-12 Mohasco Ind Inc Method and apparatus for the production of paper yarn
US3161560A (en) * 1961-01-04 1964-12-15 Int Paper Co Extrusion coated paper and method of making the same
US3219507A (en) * 1961-02-20 1965-11-23 Magee Carpet Co Method of applying plastic sheet to pile fabric backing

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3540963A (en) * 1964-05-18 1970-11-17 Johnson & Johnson Method of making a composite absorbent laminate
US3449187A (en) * 1964-12-08 1969-06-10 Bobkowicz E Method and apparatus for making nonwoven fabrics
US3959059A (en) * 1968-02-16 1976-05-25 Leon Rollin Alexander Method and apparatus for flocking continuous webs
US3983202A (en) * 1969-06-26 1976-09-28 Shell Oil Company Manufacture of synthetic fibers and yarns
DE2312816A1 (de) * 1973-03-15 1975-02-06 Basf Ag Verfahren zur herstellung von halbzeug aus faserverstaerkten thermoplastischen kunststoffen
US3939873A (en) * 1973-08-27 1976-02-24 Exxon Research And Engineering Company Corrosion resistant glass-reinforced plastic pipe liner
US3968283A (en) * 1974-05-21 1976-07-06 Scott Paper Company Flocked filamentary element and structures made therefrom
US4623579A (en) * 1983-10-04 1986-11-18 Multi-Tex Products Corp. Yarn product with combined fluorescent-phosphorescent appearance and method
US20030096901A1 (en) * 2000-04-13 2003-05-22 Jari Aarila Polymer composition for pipes
US6968866B2 (en) * 2000-10-10 2005-11-29 Taiyo Kogyo Corporation Tent fabric, twisted union yarn of kenaf, and process for producing the same
US20100000195A1 (en) * 2008-07-02 2010-01-07 AG Technologies, Inc. Process for manufacturing yarn made from a blend of polyester fibers and silver fibers
US20100000196A1 (en) * 2008-07-02 2010-01-07 AG Technologies, Inc. Process for manufacturing yarn made from a blend of fibers of cotton, nylon and silver
US7882688B2 (en) 2008-07-02 2011-02-08 AG Technologies, Inc. Process for manufacturing yarn made from a blend of polyester fibers and silver fibers
US7886515B2 (en) 2008-07-02 2011-02-15 AG Technologies, Inc. Process for manufacturing yarn made from a blend of fibers of cotton, nylon and silver
CN115354427A (zh) * 2022-01-20 2022-11-18 浙江理工大学 一种复合纸纱的制备装置及其制备方法

Also Published As

Publication number Publication date
BR7018045D0 (pt) 1973-01-23
CH405123A (fr) 1965-09-15
GB1000998A (en) 1965-08-11
US3481132A (en) 1969-12-02
CH672163A4 (fr) 1965-09-15
DE1560646A1 (de) 1972-03-30
ES288492A1 (es) 1963-10-16

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