US3492389A - Technique for producing synthetic bulk yarns - Google Patents

Technique for producing synthetic bulk yarns Download PDF

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Publication number
US3492389A
US3492389A US724533A US3492389DA US3492389A US 3492389 A US3492389 A US 3492389A US 724533 A US724533 A US 724533A US 3492389D A US3492389D A US 3492389DA US 3492389 A US3492389 A US 3492389A
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United States
Prior art keywords
yarns
bulk
twist
yarn
ribbon
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Expired - Lifetime
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US724533A
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English (en)
Inventor
Morton I Port
Bernard L Schwartz
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Avisun Corp
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Avisun Corp
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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
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • 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
    • D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
    • D01D5/423—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments by fibrillation of films or filaments
    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/47—Processes of splitting film, webs or sheets

Definitions

  • ABSTRACT OF THE DISCLOSURE A technique for converting synthetic polymeric material into a plurality of bulk yarn packages, wherein the material is first extruded into a film-like web which is then stretch-oriented to an orientation point at which the material is susceptible to fibrillation, the web then being slit before or after orientation into individual ribbons, each of which is thereafter conveyed through a heating zone and a false twister, such that the twisting action stresses the ribbon to fibrillate same into multiple filaments which are curled or otherwise distorted as a result of heat-setting, thereby forming a multifilament, bulked yarn which is wound into a package.
  • This invention relates generally to the manufacture of bulk yarns, and more particularly to a method for converting a web of thermoplastic polymeric material into multi-filament bulk yarns.
  • bulk yarns is generally applied to continuous, multi-filament yarns that have been processed to give greatly increased mass or bulk per unit length.
  • the crimped type such as Textralized and Spunized yarn, is produced by stuffer-box or gear crimping techniques, and is characterized by the fact that individual fibers, when fully contracted, show very small random undulations along their length.
  • the individual fibers exhibit many complete loops.
  • the bulk yarn has a wavy configuration.
  • the end uses of bulk yarns depend on their inherent characteristics, and while crimp-type yarns in heavy deniers are used in rugs, carpets and for upholstery and industrial fabrics of various types, the loop type is more widely used in apparel items, such as sport jackets, ties and scarves, Whereas the crinkle type finds its uses in ladies seamless hosiery and sweaters.
  • Each type of bulk ice yarn has a particular appearance, hand and texture, as well as moisture absorption characteristics, and these properties are taken into account in the selection of a bulk yarn for a specific purpose.
  • texturizing The technique by which the continuous filaments are converted into bulk yarns is known as texturizing. This technique depends on the ability of thermoplastic filaments to be deformed, heat-set and developed, and it acts permanently to introduce crimps, coils, loops, or crinkles into otherwise continuous filaments. Not only does texturizing make it possible with synthetic yarns to simulate the characteristics of spun yarns, but is provides bulk yarns having improved pill resistance, greater durability, as well as stretch and wash-and-wear qualities.
  • a continuous, multi-filament yarn produced by standard fiber-making techniques.
  • the raw material in molten form which may be, for example, a polyamide, a polyester or an acrylic, is extruded through a pattern of fine holes in a spinneret to yield a multiplicity of fine continuous filaments which are then wound upon a spin bobbin.
  • the m ulti-filament yarn is unwound and stretchoriented by a drawing process to improve the tensile strength thereof, the multi-filament yarn being again wound on a bobbin.
  • To texturize this yarn it is again unwound, this time the yarn passing through an appropriate stutter-box or other form of texturizing mechanism.
  • the conventional technique for making bulk yarns involves a series of distinct, discontinuous steps, the yarn being unwound at the beginning and rewound at the end of each step. Accordingly, it is the main object of the present invention to provide a novel process for making bulk yarn in a rapid, uninterrupted, sequential operation for transforming molten raw material into bulk yarn.
  • the raw material for forming the bulk yarn is rendered molten and extruded through a suitable extruder 10 to form a film-like sheet or Web 11.
  • the raw material may be of any known form of molecularly orientable, thermoplastic polymeric material, such as polyethylene, polypropylene, polyamide,
  • polyester or any other suitable resin having an orientable molecular structure.
  • Polymers are synthetic substances composed of large molecules that have been formed by the union of a group of single molecules with one another.
  • the manner in which the raw material is converted into web form is entirely conventional, and any standard equipment may be used for this purpose.
  • Web 11 is pulled from extruder by feed roll 12, the web being cooled before it reaches the roll so that it is below its softening point. Longitudinal orientation is then effected by the process of drawing to irreversibly stretch the web and thereby increase its tensile strength considerably. This is accomplished by a cooled draw roll 13 whose peripheral speed is greater than that of a heated feed roll 12, the ratio bet-ween the two rolls being termed the draw ratio.
  • the draw ratio is preferably in excess of 5 to 1, so that the material will have a definite tendency to filamentize longitudinally when later stressed or worked. In the case of other materials, the draw ratio is chosen to obtain the same effect.
  • the stretch-oriented web 14 emerging from draw roll 13 is conveyed into a slitter mechanism 15 where it is divided into a plurality of individual fiat ribbons R R R R,, the ribbons having a width appropriate to the final denier of the yarn.
  • slitting may be effected prior to orientation.
  • each ribbon is then subjected to a working operation which serves to rupture the cross or lateral bonding of the polymeric ribbon and thereby to separate the longitudinally-oriented chain molecules into individual fibers or filaments.
  • the ribbons are fed into a bank of false-twist spindles S to S one for each ribbon, through respective heating zones Z through Z
  • the combined action of the false-twist spindles and the heating zones acts to both fibrillate and texturize the ribbons, so that emerging from the exit side of the false-twist spindles are multi-filament, bulked yarns Y; to Y which are then wound on individual spindles in a bank 16 thereof.
  • the bulk yarns may be wound on a beam for warp yarns or onto suitable packages for use as filling yarns.
  • a false-twist spindle consists of a rapidly revolving tube with an eccentrically located guide or book.
  • the ribbon to be false-twisted is led from slitter 15, passed around the guide or hook, and passed through the tube to the collection package.
  • the false-twist spindle is controllable to produce as many as thirty-five turns of twist per inch. This gives rise to a considerable rubbing action which works or stresses the highly oriented ribbon and causes it to fibrillate. Since the twist occurs at the entry side of the false-twist spindle in advance of the heating zone, what actually passes through the heating zone is not a monofilament ribbon, but one composed of a cluster of fine filaments. To prevent the twist at the entry side from running back to the slitter, nip rolls 17 or equivalent means are provided adjacent the exit of the slitter 15.
  • the heating zones which precede the false-twist spindles can be heated by electrical resistance coils, air, steam, or other heat-exchange fluids.
  • the temperature of the heated area must be constantly and carefully controlled, and is adjusted to the speed of ribbon travel. Heat can be transferred by direct contact or by radiation.
  • the use of the false-twist spindles to effect efficient fibrillation need not be accompanied by heat-setting to simultaneously bulk the yarn, for in some instances, one may wish to produce fibrillated ribbons in which the filaments are unmodified.
  • the fibrillated yarns may have finishing agents or lubricants applied thereto to facilitate subsequent processing, such as weaving.
  • Such fibrillated ribbons are useful, for example, as face yarns for tufted rugs.
  • the advantage of the false-twist spindle technique for fibrillation, as against the use of rotating brushes or needles of the type heretofore used, is that one can attain better control of fibrillation, for by varying the degree of twist and the speed of advance, one may obtain uniform fibrillation to the extent desired.
  • the process for producing bulk yarns in accordance with the invention involves the production of a broad, thermoplastic, film-like web by extrusion, followed by stretch-drawing to form an oriented web of narrower width, which web is slit before or after orientation into flat ribbons appropriate to the denier of the final yarn, the oriented ribbons being individually worked in a falsetwist spindle operating in conjunction with a heater serving to fibrillate the ribbon into multiple filaments which are curled to produce a bulk yarn.
  • a process for continuously producing a plurality of packages of bulk yarns from polymeric material capable of being molecularly oriented comprising the continuous steps of:
  • polymeric material is selected from the class consisting of polyethylene, polypropylene, polyamide and polyester.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
US724533A 1968-04-26 1968-04-26 Technique for producing synthetic bulk yarns Expired - Lifetime US3492389A (en)

Applications Claiming Priority (1)

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US72453368A 1968-04-26 1968-04-26

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US3492389A true US3492389A (en) 1970-01-27

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US (1) US3492389A (enrdf_load_stackoverflow)
JP (1) JPS4930851B1 (enrdf_load_stackoverflow)
BE (1) BE732145A (enrdf_load_stackoverflow)
DE (1) DE1920378A1 (enrdf_load_stackoverflow)
FR (1) FR2007028A1 (enrdf_load_stackoverflow)
GB (1) GB1225589A (enrdf_load_stackoverflow)
NL (1) NL6906159A (enrdf_load_stackoverflow)

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3630816A (en) * 1969-07-25 1971-12-28 Chevron Res Nonwoven sheets made from rectangular cross section monofilaments
US3761552A (en) * 1971-02-12 1973-09-25 Chevron Res Process for making moresque yarn from polymer film
US3927957A (en) * 1972-12-21 1975-12-23 Chevron Res Apparatus for making yarn from polymer film
US4009235A (en) * 1975-07-14 1977-02-22 Eastman Kodak Company Method for reclaiming extruded plastic resins
US4483727A (en) * 1983-02-07 1984-11-20 Celanese Corporation High modulus polyethylene fiber bundles as reinforcement for brittle matrices
US4524101A (en) * 1983-02-07 1985-06-18 Celanese Corporation High modulus polyethylene fiber bundles as reinforcement for brittle matrices
EP0017261B1 (en) * 1979-01-31 1985-06-19 Standard Oil Company Method and apparatus for winding and twisting yarn
US4668566A (en) * 1985-10-07 1987-05-26 Kimberly-Clark Corporation Multilayer nonwoven fabric made with poly-propylene and polyethylene
US4753834A (en) * 1985-10-07 1988-06-28 Kimberly-Clark Corporation Nonwoven web with improved softness
US4778460A (en) * 1985-10-07 1988-10-18 Kimberly-Clark Corporation Multilayer nonwoven fabric
US5578373A (en) * 1990-11-01 1996-11-26 Nippon Oil Co., Ltd. Split polyethylene stretched material and process for producing the same
US5925434A (en) * 1997-06-12 1999-07-20 Bp Amoco Corporation Tuftable backing and carpet construction
WO2010069777A1 (de) * 2008-12-20 2010-06-24 Oerlikon Textile Gmbh & Co. Kg Vorrichtung zum texturieren und aufwickeln mehrerer fäden
US20110308051A1 (en) * 2009-09-23 2011-12-22 Jing-Jyr Lin Method for manufacturing weaving material from nonwoven
US20150203232A1 (en) * 2012-10-22 2015-07-23 Encore Packaging Llc Stretch Film Roping
US20190062949A1 (en) * 2016-03-03 2019-02-28 Teijin Aramid B.V. Process and device for splitting a tape
US10843827B2 (en) 2016-11-06 2020-11-24 Encore Packaging Llc Stretch film processing to replace strapping
CN114108114A (zh) * 2021-10-18 2022-03-01 浙江古纤道股份有限公司 一种裂离型超细扁平丝的制备方法
US11673710B2 (en) 2021-01-14 2023-06-13 Encore Packaging Llc Securing apparatus for packaging and shipping

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2458978A2 (fr) * 1979-06-07 1981-01-02 Commissariat Energie Atomique Procede et dispositif d'interconnexions de composants electronique
DE102009037740A1 (de) * 2009-08-17 2011-02-24 Oerlikon Textile Gmbh & Co. Kg Verfahren und Vorrichtung zur Herstellung eines Grasgarnes

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2700657A (en) * 1951-11-13 1955-01-25 Dow Chemical Co Melt-spinnable, fiber forming blend of polystyrene and specific styrene-acrylonitrile interpolymers
US2863280A (en) * 1952-05-23 1958-12-09 Ubbelohde Leo Method of crimping filaments
US2869312A (en) * 1955-02-11 1959-01-20 American Enka Corp Yarn heating apparatus
US2918778A (en) * 1957-04-19 1959-12-29 Universal Winding Co Textile machine
US2954587A (en) * 1954-05-29 1960-10-04 Rasmussen Ole-Bendt Method of producing fibrous materials
CA624991A (en) * 1961-08-01 E.I. Du Pont De Nemours And Company Yarns from fibrillatable films
US3007765A (en) * 1957-03-05 1961-11-07 Shell Oil Co Drawing and filamenting treatment of crystalline polymers
US3242035A (en) * 1963-10-28 1966-03-22 Du Pont Fibrillated product
US3327461A (en) * 1965-06-17 1967-06-27 Turbo Machine Co Apparatus and method for producing false twist in yarn
US3330104A (en) * 1964-09-30 1967-07-11 Du Pont False twist spindle with auxiliary reverse-twist element
US3336174A (en) * 1965-04-06 1967-08-15 Eastman Kodak Co Method of making a fibrous filter product
US3336738A (en) * 1962-12-03 1967-08-22 Klinger Mfg Co Ltd Apparatus for false twist-crimping of yarn
US3382663A (en) * 1964-12-22 1968-05-14 Shell Oil Co Manufacture of fibrillated strands

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA624991A (en) * 1961-08-01 E.I. Du Pont De Nemours And Company Yarns from fibrillatable films
US2700657A (en) * 1951-11-13 1955-01-25 Dow Chemical Co Melt-spinnable, fiber forming blend of polystyrene and specific styrene-acrylonitrile interpolymers
US2863280A (en) * 1952-05-23 1958-12-09 Ubbelohde Leo Method of crimping filaments
US2954587A (en) * 1954-05-29 1960-10-04 Rasmussen Ole-Bendt Method of producing fibrous materials
US2869312A (en) * 1955-02-11 1959-01-20 American Enka Corp Yarn heating apparatus
US3007765A (en) * 1957-03-05 1961-11-07 Shell Oil Co Drawing and filamenting treatment of crystalline polymers
US2918778A (en) * 1957-04-19 1959-12-29 Universal Winding Co Textile machine
US3336738A (en) * 1962-12-03 1967-08-22 Klinger Mfg Co Ltd Apparatus for false twist-crimping of yarn
US3242035A (en) * 1963-10-28 1966-03-22 Du Pont Fibrillated product
US3330104A (en) * 1964-09-30 1967-07-11 Du Pont False twist spindle with auxiliary reverse-twist element
US3382663A (en) * 1964-12-22 1968-05-14 Shell Oil Co Manufacture of fibrillated strands
US3336174A (en) * 1965-04-06 1967-08-15 Eastman Kodak Co Method of making a fibrous filter product
US3327461A (en) * 1965-06-17 1967-06-27 Turbo Machine Co Apparatus and method for producing false twist in yarn

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3630816A (en) * 1969-07-25 1971-12-28 Chevron Res Nonwoven sheets made from rectangular cross section monofilaments
US3761552A (en) * 1971-02-12 1973-09-25 Chevron Res Process for making moresque yarn from polymer film
US3927957A (en) * 1972-12-21 1975-12-23 Chevron Res Apparatus for making yarn from polymer film
US4009235A (en) * 1975-07-14 1977-02-22 Eastman Kodak Company Method for reclaiming extruded plastic resins
EP0017261B1 (en) * 1979-01-31 1985-06-19 Standard Oil Company Method and apparatus for winding and twisting yarn
US4483727A (en) * 1983-02-07 1984-11-20 Celanese Corporation High modulus polyethylene fiber bundles as reinforcement for brittle matrices
US4524101A (en) * 1983-02-07 1985-06-18 Celanese Corporation High modulus polyethylene fiber bundles as reinforcement for brittle matrices
US4668566A (en) * 1985-10-07 1987-05-26 Kimberly-Clark Corporation Multilayer nonwoven fabric made with poly-propylene and polyethylene
US4753834A (en) * 1985-10-07 1988-06-28 Kimberly-Clark Corporation Nonwoven web with improved softness
US4778460A (en) * 1985-10-07 1988-10-18 Kimberly-Clark Corporation Multilayer nonwoven fabric
US5578373A (en) * 1990-11-01 1996-11-26 Nippon Oil Co., Ltd. Split polyethylene stretched material and process for producing the same
US5925434A (en) * 1997-06-12 1999-07-20 Bp Amoco Corporation Tuftable backing and carpet construction
WO2010069777A1 (de) * 2008-12-20 2010-06-24 Oerlikon Textile Gmbh & Co. Kg Vorrichtung zum texturieren und aufwickeln mehrerer fäden
CN102257196B (zh) * 2008-12-20 2013-06-26 欧瑞康纺织有限及两合公司 用于多根纱线的卷曲变形和卷绕的设备
US20110308051A1 (en) * 2009-09-23 2011-12-22 Jing-Jyr Lin Method for manufacturing weaving material from nonwoven
US8807175B2 (en) * 2009-09-23 2014-08-19 Jing-Jyr Lin Method for manufacturing weaving material from nonwoven
US20150203232A1 (en) * 2012-10-22 2015-07-23 Encore Packaging Llc Stretch Film Roping
US10279945B2 (en) * 2012-10-22 2019-05-07 Encore Packaging Llc Stretch film roping
US20190062949A1 (en) * 2016-03-03 2019-02-28 Teijin Aramid B.V. Process and device for splitting a tape
US11208737B2 (en) * 2016-03-03 2021-12-28 Teijin Aramid B.V. Process and device for splitting a tape
US10843827B2 (en) 2016-11-06 2020-11-24 Encore Packaging Llc Stretch film processing to replace strapping
US11673710B2 (en) 2021-01-14 2023-06-13 Encore Packaging Llc Securing apparatus for packaging and shipping
CN114108114A (zh) * 2021-10-18 2022-03-01 浙江古纤道股份有限公司 一种裂离型超细扁平丝的制备方法

Also Published As

Publication number Publication date
DE1920378A1 (de) 1970-02-12
JPS4930851B1 (enrdf_load_stackoverflow) 1974-08-16
FR2007028A1 (enrdf_load_stackoverflow) 1970-01-02
NL6906159A (enrdf_load_stackoverflow) 1969-10-28
BE732145A (enrdf_load_stackoverflow) 1969-10-01
GB1225589A (enrdf_load_stackoverflow) 1971-03-17

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