US3444682A - Tow treatment for preparation of high-bulk yarns - Google Patents

Tow treatment for preparation of high-bulk yarns Download PDF

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Publication number
US3444682A
US3444682A US571299A US3444682DA US3444682A US 3444682 A US3444682 A US 3444682A US 571299 A US571299 A US 571299A US 3444682D A US3444682D A US 3444682DA US 3444682 A US3444682 A US 3444682A
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United States
Prior art keywords
tow
segments
yarn
roll
length
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US571299A
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English (en)
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Ezio Polacco
Francesco Denti
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ACSA APPLIC CHIMICHE SpA
ACSA APPLICAZIONI CHIMICHE SPA
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ACSA APPLIC CHIMICHE SpA
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/20—Formation of filaments, threads, or the like with varying denier along their length
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/18—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by combining fibres, filaments, or yarns, having different shrinkage characteristics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
    • D02J1/225—Mechanical characteristics of stretching apparatus
    • D02J1/226—Surface characteristics of guiding or stretching organs
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904—Staple length fiber
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2973—Particular cross section
    • Y10T428/2976—Longitudinally varying

Definitions

  • staple fibers of the aforesaid type after having been shrunk 1n tensionless condition and yarns and fabrics comprised of such staple, Further, processes for the preparation of such staple predicated upon heat plasticizing a tow of oriented and relaxed filaments in repeating spaced segments, then stretching said tow, cutting the same into staple and, where appropriate, shrinking the same.
  • This invention relates to a process for the treatment of two for the preparation of novel high-bulk acrylic yarns.
  • this invention relates to the prepmatron of high-bulk yarns comprising acrylonitrile polymers which possess uniform dyeing characteristics and texture.
  • High bulk acrylic yarns are known in the art to provide fabrics having enhanced apparent value and cover. They are commonly provided by blending fibers having different physical characteristics such as shrinking and filament configuration, whether mechanically or self-induced. In the latter case bifilar or bicomponent fibers wherein the two components shrink differently to thereby cause crimp formation can be blended with monocomponent fibers to provide yarns from which fabrics, including carpets, having excellent cover and apparent value can be manufactured. While this technique is widely employed and provides excellent products, economics and processing difiiculties demand other methods for producing high bulk yarns.
  • an alternate means for preparation of high bulk yarns lies in the blending of fibers which are different at least to the extent that they possess considerable variation in their ability to shrink upon treatment with heat.
  • One known technique to achieve this type of blend lies in feeding separate tows having differing heat shrinkage properties to a staple cutter to thereby achieve a staple fiber blend in the desired proportion.
  • One salient difliculty with such a blend lies in the observation that in subsequent textile processing operations, such as carding, combing and the like, the high shrinking fibers tend to migrate toward the core of the yarn thereby to create a yarn characterized, more or less, by a high shrinking core and even though such yarns develop bulk when subjected to heat treatment, they suffer losses of strength and aesthetic value,
  • Such a tow may have, for
  • Another object of the invention lies in the provision of a novel process for treatment of tow comprising filaments of acrylonitrile polymers to provide high-bulk yarns.
  • this invention has as its object a novel staple fiber component of high-bulk yarns.
  • the tow having repeating spaced segments of fiber which have been stretched to a greater degree than the remaining segments may be prepared by continuously passing the tow over a heated roll having a channeled or tooth-like surface so that when the tow is passed over the roll only certain segments of the tow come into contact with the heated surface to thereby become plasticized.
  • the tow having spaced plasticized segments is passed from the channeled roll in the plasticized condition to a set of draw rolls moving at a greater peripheral speed than the channeled roll thereby causing the partially plasticized tow to stretch in those segments which are in a heat plasticized state.
  • the tow obtained according to the process of this invention is characterized in that it is composed of individual filaments having regularly alternating stretched segments B which segments are heat shrinkable and segments A which receive no stretch according to the instant invention and which are not heat shrinkable or heat shrinkable only to a minor degree.
  • the tow can then be cut to staple fiber of a desired length wherein each fiber component has high and low shrinkage segments along its longitudinal axis. Heat shrinkage of yarns prepared from these staple fibers creates a novel yarn which possesses uniform dyeing characteristics, high strength and high bulk.
  • the lengths of the high shrinking and low shrinking segments built into the tow (and the resulting ratio of B/A) must be chosen with consideration of characteristics desired in the final yarn such as bulk, fiber length, degree of heat shrinkage and the like.
  • the length of the high shrinking segments should be between about 15 and millimeters.
  • the length of low shrinking segments should lie between about 15 and 100 millimeters.
  • the choice of the lengths of the different segments should be such that the sum of A and B equals the cut length of the staple desired for conventional textile processing generally between about 80 and millimeters.
  • FIGURE 1 represents a schematic of yarn treatment according to the instant process
  • FIGURE 2 represents an illustration of a length of filament treated according to the instant process
  • FIGURE 3 represents the length of filament shown in FIGURE 2 treated according to this process and having been subsequently heat shrunk and
  • FIGURE 4 is a graph showing the stress-strain curves of yarn prepared according to this invention and an unbulked yarn.
  • FIGURE 1 illustrates the .process of this invention wherein a tow 1 of a previously uniformly stretched and relaxed acrylonitrile polymer fiber is continuously passed .to feed rolls 2 and 3 and then to an idler roll 4 from whence the tow is passed on to the heated surface of channeled roll 5 which rotates (clockwise direction in FIGURE 1) at the same peripheral speed as feed rolls 2 and 3. Portions of the tow 1 contact heated roll 5 at heated teeth or contact elements represented by tooth or element 9 which may be an integral or permanent part of roll 5 or it may be attached as by screw, bolt or other means 10.
  • segment A of tow 1 does not contact the surface of roll 5, while segment B of tow 1 contacts the heated surface of the roll as illustrated and is heated to the extent that it is plasticized.
  • the peripheral lengths of the spacings between the several teeth may vary or be uniform. Moreover, their peripheral lengths may be the same as or differ from the peripheral lengths of the teeth.
  • the profile of the channeled or toothed roll and the number of teeth or raised contact elements it is possible to obtain a wide variety of combinations of stretch, stretch ratios, ratios between stretched and unstretched segments, and the like.
  • the outer surface of the raised contact elements have a rectangular shape although this is not a critical aspect of the invention so long as there is suflicient contact surface to transfer heat to the tow.
  • Roll 5 may be heated by electrical means, by high pressure steam, or by other suitable means for elevating the temperature of the teeth or raised contact elements to cause suitable softening or plasticizing of the filamentary material passing in contact therewith.
  • the temperatures necessary to plasticize the filaments or tow lie between about 60 and about 200 C., more typically between about 90 and about 180 C.
  • the individual filaments of tow 1 may be characterized by segments along their lengths having sharply varying denier caused by differential stretching as depicted in FIGURE 2.
  • a in FIGURE 2 represents that portion of the filament which is essentially unmodified by passing over roll 5 whereas adjacent segment B has been heat plasticized and stretched to thereby cause some reduction in denier at sharply defined points along the length of the filament.
  • the filament depicted in FIGURE 2 to heat shrinkage the differences in denier disappear for all practical purposes and the filament represents a substantially uniform denier as depicted in FIGURE 3 having essentially uniform segment AB"A.
  • this invention is applicable to yarns comprised of filaments of acrylonitrile polymers.
  • acrylonitrile polymers include polyacrylonitrile and interpolymers comprising at least about weight percent of acrylonitrile and up to about 15 percent of one or more monoethylenically unsaturated monomers interpolymerizable therewith.
  • Comonomers such as methyl methacrylate, vinyl acetate, styrene, vinylidene chloride, vinyl bromide, vinylpyridine, alkenyl and alkenyloxysulfonic acids, and the like may be interpolymerized in minor amounts with acrylonitrile according to means well known in the art to form useful fiber forming polymers.
  • the polymers of acrylonitrile, useful for this invention may then be dissolved to form spinning solutions in dimethylsulfoxide, dimethylformamide, dimethylacetamide or the like and thereafter extruded by wet, dry, or dry jet-wet methods to form a multi-filament bundle of synthetic filaments which is coagulated, washed, stretched, dried and relaxed by any of several well known prior art processes.
  • the tow treated according to this invention may be given a mechanical crimp after treatment on roll 5 to facilitate handling in subsequent textile operations such as combing and carding.
  • roll 5 may be used to replace the heating plates in machines such as the Turbo-Stapler, the Seydel or Termatex converters and other machines employed to convert tow into top.
  • the top thus obtained is comprised of individual fibers each having high and low shrinking segments along their longitudinal axes.
  • Example I A 40,000 filament tow of a polymer of 94 weight percent acrylonitrile and 6 weight percent vinyl acetate having a total denier of 120,000 having been stretched and relaxed was fed to a pair of feed rolls corresponding to roll 2 and 3 in FIGURE 1 and thereafter passed over a channeled roll corresponding to roll 5 heated to 130 C. and on to draw rolls 7 and 8.
  • the peripheral speed of rolls 2 and 3 was 23 meters per minute while rolls 7 and 8 were run at a peripheral speed of 27.5 meters per minute to give the tow a 1.2x stretch.
  • the hot channeled roll had an outer diameter of 300 millimeters with uniform raised contact surfaces of 30 millimeter spaced surfaces and channels spacing the raised contact surfaces of 55 millimeters, the ratio of heated contact periphery to spaces being 30/ 55
  • the tow thus treated was thereafter passed to staple cutter and cut to a length of millimeters to provide individual staple fibers having both stretched and unstretched segments.
  • the staple fiber was then processed according to the worsted system to provide a yarn having the following properties:
  • Metric count(nm.) 27/2 Twist 420 Z+275 S Bulk 18 fabric so obtained was compared with a knitted fabric of the same compactness the fibers of which had not been treated according to the process of this invention.
  • the novel fabric exhibited better stitch clarity and pilling (after hours of Random Tumbler) of 12 mg./dm. as compared with 14 mg./drn. for the control fabric. Handle of the two fabrics was essentially equivalent.
  • Example II The procedure of Example I was repeated using a 100,000 denier tow comprised of 20,000 filaments under the following condition:
  • Example 111 Repeating Example I with a 480,000 denier tow comprised of 60,000 filaments a novel yarn was prepared under the following conditions:
  • Example IV A 480,000 denier tow comprised of 160,000 acrylonitrile/vinyl acetate (94/6) filaments was processed on a TurboStapler in which the heating plates had been replaced by a channel roll under the following conditions:
  • FIGURE 4 shows stress-strain curves wherein C represents yarn prepared according to this example and D represents yarn prepared from conventional Turbo-tip.
  • the break length is the length of yarn in kilometers required to break the yarn under its own weight.
  • the curve plotted for the yarn prepared from tow treated according to the instant invention exhibits a more uniform development.
  • Staple fibers cut from a tow of wholly oriented filaments of a polymer of acrylonitrile having sharply defined alternate segments B of reduced denier along its longitudinal axis and said segments B being of less than staple fiber length and having been stretched to lengths about 1.1 to 2 times greater than the lengths of the remaining segments A of the tow, said remaining segments A also being of less than staple length, with the lengths of the respective segments being such that the sum of A and B equals the cut length of the staple.
  • a wholly oriented staple fiber of a polymer of acrylonitrile comprised of sharply defined alternate segments B and A along its longitudinal axis, said segment B being of reduced denier with respect to segment A by reason of its having been stretched to a length about 1.1 to 2 times as great as that of the said segment A.
  • Staple fibers according to claim 2 exhibiting substantially homogeneous cross-sections along their longitudinal axes by reason of their additionally having been shrunk in tensionless condition, whereby there were effected substantially uniform deniers thereof.
  • High-strength, high-bulk yarn susceptible to more uniform dyeing comprised of the staple fibers of claim 3.
  • a process for the preparation of high-strength, high-bulk yarn susceptible to more uniform dyeing comprising heat plasticizing a tow of oriented and relaxed filaments of a polymer of acrylonitrile in repeating spaced segments along the longitudinal axis of the tow, thereafter stretching said tow about 1.1 to 2 times while the heat plasticized repeating spaced segments thereof are still in a plasticized condition, and then cutting the said tow into staple length of from between 8 0 to 120 millimeters to form staple fibers, forming a yarn structure of said wholly oriented staple fibers and thence shrinking the 8 References Cited UNITED STATES PATENTS 2,296,394 9/ 1942 Meloon.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Preliminary Treatment Of Fibers (AREA)
US571299A 1965-08-10 1966-08-09 Tow treatment for preparation of high-bulk yarns Expired - Lifetime US3444682A (en)

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IT1819865 1965-08-10

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US (1) US3444682A (xx)
BE (1) BE684818A (xx)
CH (1) CH456024A (xx)
GB (1) GB1155141A (xx)
IL (1) IL26301A (xx)
LU (1) LU51739A1 (xx)
NL (1) NL6610455A (xx)
SE (1) SE324032B (xx)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3541197A (en) * 1968-05-13 1970-11-17 Phillips Petroleum Co Production of net-like structures
US3673650A (en) * 1969-05-19 1972-07-04 Bemberg Spa Method for producing a thermoplastic synthetic yarn having a latent crimp
USRE28843E (en) * 1968-02-19 1976-06-08 Rhone-Poulenc-Textile, S.A. Textured polyethylene terephthalate yarns
US3967441A (en) * 1973-04-28 1976-07-06 Unitika Ltd. Yarns and process for production thereof
US4000960A (en) * 1972-08-04 1977-01-04 Mitsubishi Rayon Co., Ltd. Apparatus for manufacturing synthetic tow for stretch-cut spinning process
US4043108A (en) * 1976-09-16 1977-08-23 E. I. Du Pont De Nemours And Company Process
US4263368A (en) * 1974-07-15 1981-04-21 Toray Industries, Inc. Process for producing a potentially bulky yarn
US4355749A (en) * 1979-10-02 1982-10-26 Hacoba Textilmaschinen Gmbh & Co. Kg Feeding apparatus for wet yarn
US4382992A (en) * 1974-07-15 1983-05-10 Toray Industries, Inc. Potentially bulky yarn
US4654021A (en) * 1985-10-29 1987-03-31 Mobil Oil Corporation Making intermittent orientation draw tape for bags
WO2015176997A1 (de) * 2014-05-20 2015-11-26 Itv Denkendorf Produktservice Gmbh Fäden mit variierendem fadendurchmesser sowie herstellungsverfahren für solche fäden
CN105926101A (zh) * 2016-06-27 2016-09-07 嘉兴胜邦机械设备有限公司 用于在复合丝工艺中形成竹节丝的纺丝装置以及利用纺丝装置制作竹节丝的方法
CN105937063A (zh) * 2016-06-27 2016-09-14 嘉兴胜邦机械设备有限公司 用于在全拉伸丝工艺中形成竹节丝的纺丝装置
CN105970319A (zh) * 2016-06-27 2016-09-28 嘉兴胜邦机械设备有限公司 加热成型辊、纺丝装置、制造加热成型辊的方法、和制作竹节丝的方法
US20170107651A1 (en) * 2015-10-16 2017-04-20 Avintiv Specialty Materials Inc. Nonwovens having aligned segmented fibers
CN108584532A (zh) * 2018-06-01 2018-09-28 嘉兴市华益股份有限公司 一种纱线传送牵拉机构
CN116446085A (zh) * 2023-04-26 2023-07-18 浙江佳宝聚酯有限公司 一种涤纶fdy长丝复合仿毛纱线的生产方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2296394A (en) * 1940-11-22 1942-09-22 Du Pont Manufacture of novelty artificial yarn
US2917779A (en) * 1955-05-13 1959-12-22 Hoechst Ag Process for preparing improved thin shaped structures, such as filaments or foils, from linear polyesters
US2952116A (en) * 1955-07-26 1960-09-13 Textile Licensing Company Processing yarns
US2975474A (en) * 1958-06-11 1961-03-21 Du Pont Process and apparatus for preparing novelty yarns
US3017684A (en) * 1956-01-24 1962-01-23 Deering Milliken Res Corp Textile materials and method of making the same
US3116197A (en) * 1956-08-31 1963-12-31 Du Pont Nubbed filament and dyed fabric of same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2296394A (en) * 1940-11-22 1942-09-22 Du Pont Manufacture of novelty artificial yarn
US2917779A (en) * 1955-05-13 1959-12-22 Hoechst Ag Process for preparing improved thin shaped structures, such as filaments or foils, from linear polyesters
US2952116A (en) * 1955-07-26 1960-09-13 Textile Licensing Company Processing yarns
US3017684A (en) * 1956-01-24 1962-01-23 Deering Milliken Res Corp Textile materials and method of making the same
US3116197A (en) * 1956-08-31 1963-12-31 Du Pont Nubbed filament and dyed fabric of same
US2975474A (en) * 1958-06-11 1961-03-21 Du Pont Process and apparatus for preparing novelty yarns

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE28843E (en) * 1968-02-19 1976-06-08 Rhone-Poulenc-Textile, S.A. Textured polyethylene terephthalate yarns
US3541197A (en) * 1968-05-13 1970-11-17 Phillips Petroleum Co Production of net-like structures
US3673650A (en) * 1969-05-19 1972-07-04 Bemberg Spa Method for producing a thermoplastic synthetic yarn having a latent crimp
US4000960A (en) * 1972-08-04 1977-01-04 Mitsubishi Rayon Co., Ltd. Apparatus for manufacturing synthetic tow for stretch-cut spinning process
US3967441A (en) * 1973-04-28 1976-07-06 Unitika Ltd. Yarns and process for production thereof
US4263368A (en) * 1974-07-15 1981-04-21 Toray Industries, Inc. Process for producing a potentially bulky yarn
US4382992A (en) * 1974-07-15 1983-05-10 Toray Industries, Inc. Potentially bulky yarn
US4043108A (en) * 1976-09-16 1977-08-23 E. I. Du Pont De Nemours And Company Process
US4355749A (en) * 1979-10-02 1982-10-26 Hacoba Textilmaschinen Gmbh & Co. Kg Feeding apparatus for wet yarn
US4654021A (en) * 1985-10-29 1987-03-31 Mobil Oil Corporation Making intermittent orientation draw tape for bags
WO2015176997A1 (de) * 2014-05-20 2015-11-26 Itv Denkendorf Produktservice Gmbh Fäden mit variierendem fadendurchmesser sowie herstellungsverfahren für solche fäden
US10889921B2 (en) * 2015-10-16 2021-01-12 Avintiv Specialty Materials, Inc. Nonwovens having aligned segmented fibers
US11802358B2 (en) 2015-10-16 2023-10-31 Avintiv Specialty Materials Inc. Nonwovens having aligned segmented fibers
US11280035B2 (en) 2015-10-16 2022-03-22 Avintiv Specialty Materials Inc. Nonwovens having aligned segmented fibers
US20170107651A1 (en) * 2015-10-16 2017-04-20 Avintiv Specialty Materials Inc. Nonwovens having aligned segmented fibers
CN105937063A (zh) * 2016-06-27 2016-09-14 嘉兴胜邦机械设备有限公司 用于在全拉伸丝工艺中形成竹节丝的纺丝装置
CN105937063B (zh) * 2016-06-27 2018-07-13 嘉兴胜邦机械设备有限公司 用于在全拉伸丝工艺中形成竹节丝的纺丝装置
CN105926101B (zh) * 2016-06-27 2018-09-18 嘉兴胜邦机械设备有限公司 用于在复合丝工艺中形成竹节丝的纺丝装置以及利用纺丝装置制作竹节丝的方法
CN105970319B (zh) * 2016-06-27 2018-07-13 嘉兴胜邦机械设备有限公司 加热成型辊、纺丝装置、制造加热成型辊的方法、和制作竹节丝的方法
CN105970319A (zh) * 2016-06-27 2016-09-28 嘉兴胜邦机械设备有限公司 加热成型辊、纺丝装置、制造加热成型辊的方法、和制作竹节丝的方法
CN105926101A (zh) * 2016-06-27 2016-09-07 嘉兴胜邦机械设备有限公司 用于在复合丝工艺中形成竹节丝的纺丝装置以及利用纺丝装置制作竹节丝的方法
CN108584532A (zh) * 2018-06-01 2018-09-28 嘉兴市华益股份有限公司 一种纱线传送牵拉机构
CN116446085A (zh) * 2023-04-26 2023-07-18 浙江佳宝聚酯有限公司 一种涤纶fdy长丝复合仿毛纱线的生产方法
CN116446085B (zh) * 2023-04-26 2024-05-28 浙江佳宝聚酯有限公司 一种涤纶fdy长丝复合仿毛纱线的生产方法

Also Published As

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NL6610455A (xx) 1967-02-13
CH456024A (de) 1968-05-15
SE324032B (xx) 1970-05-19
BE684818A (xx) 1967-01-03
IL26301A (en) 1970-05-21
GB1155141A (en) 1969-06-18
LU51739A1 (xx) 1967-02-09

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