US3646745A - Method and apparatus for making staple-fiber yarns - Google Patents

Method and apparatus for making staple-fiber yarns Download PDF

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Publication number
US3646745A
US3646745A US869778A US3646745DA US3646745A US 3646745 A US3646745 A US 3646745A US 869778 A US869778 A US 869778A US 3646745D A US3646745D A US 3646745DA US 3646745 A US3646745 A US 3646745A
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roving
stage
drafting
fibers
drafted
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US869778A
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Tony Lewis Baldwin
Roy Harold Burton
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Imperial Chemical Industries Ltd
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Imperial Chemical Industries Ltd
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01H—SPINNING OR TWISTING
    • D01H5/00—Drafting machines or arrangements ; Threading of roving into drafting machine
    • D01H5/18—Drafting machines or arrangements without fallers or like pinned bars
    • D01H5/26—Drafting machines or arrangements without fallers or like pinned bars in which fibres are controlled by one or more endless aprons
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01H—SPINNING OR TWISTING
    • D01H5/00—Drafting machines or arrangements ; Threading of roving into drafting machine
    • D01H5/18—Drafting machines or arrangements without fallers or like pinned bars

Definitions

  • fiber yams from Staplefiber wings provide one or two dram 6 ing stages for the roving and a final stage which is a substan- [51] Cl 5/22 Dolh 5/2 tially zero draft stage and which wholly supports the roving 0f ..57/36, 5 i 1.6, i g its p g therethrough Th e g of the final stage is 57/156; 19/236 244-251 26] less than the effective staple length of the fibers in the roving.
  • Staple-fiber yarns are generally produced on a drafting apparatus which usually consists of one or, more often, two drafting stages. In the later case the first stage through which the roving passes commonly has a lower draft ratio than the second stage.
  • a fault which can, and often does, arise during the production of yarns composed of staple fibers by methods involving drafting and twisting is commonly referred to as a cracker, which term is used to describe a bundle of small fiber loops tightly bound together.
  • the number of crackers which occurs in a yarn is variable and so is the length of each cracker formed.
  • a cracker may vary in length, for example, from as little as 0.125 inch up to 2 inches.
  • An overlength staple fiber is a fiber, present in the roving, having a length which is in excess of the effective staple length of the majority of the staple fibers in the roving.
  • the majority of the staple fibers in a roving has the same length, i.e., the effective staple length, but the roving may also contain minority groups made up of fibers having lengths shorter than the effective staple length and fibers having lengths greater than the effective staple length.
  • the drafting conditions are chosen with the effective staple length in mind so that the majority of the staple fibers are efficiently processed.
  • the smaller staple fibers pass through the drafting apparatus without difficulty but the longer staple fibers, i.e., the overlength fibers, give rise to crackers.
  • the part played by the overlength fibers in the formation of crackers is considered to be as follows:
  • An overlength fiber present in a roving advances through the drafting apparatus at the speed imparted to it as it enters the, or the final, drafting stage even when its leading end emerges from that drafting stage, in those circumstances when the length of the overlength fiber is such that it spans that drafting stage.
  • the normal staple fibers in the roving have their speed increased as they pass through and emerge from the drafting stage. There is then a tendency for the normal staple fibers to catch on and be retarded by the overlength fiber, the result being the formation of a loop or loops of fibers due to the overfeed rate of the normal staple fibers.
  • the high degree of twist being imparted to the drafted material by the windup mechanism rolls up the loop or loops and a cracker is formed. The formation of the cracker continues until the trailing end of the overlength fiber passes through the entrance to the drafting stage or the fiber breaks.
  • Overlength fibers occur in rovings composed of natural fibers because some fibers grow to longer lengths than others.
  • overlength fibers may arise during the production of the staple fibers from a heavy denier tow of continuous filaments and may be due, for example, to differing tensions in the continuous filaments, or to nonparallelism of some of the continuous filaments as the tow passes through the cutter, or to malfunctioning of the cutter.
  • An object of the present invention is the provision of a method and apparatus for making staple-fiber yarns wherein, if overlength fibers are present in the rovings from which the yarns are made, the occurrence of cracker formation, if not eliminated, is at least greatly reduced.
  • a method of manufacturing a yarn from a roving composed of staple fibers comprises passing the roving through at least one stage in which it is subjected to a drafting operation and twisting the drafted roving to form a yarn, wherein the insertion of the twist is held off by passing the drafted roving through a further stage in which it is subjected to a substantially zero draft and is wholly supported during its travel therethrough.
  • the roving may be passed through two successive drafting stages, it being subjected to a higher draft in one stage than in the other, prior to being passed through the further stage wherein it experiences substantially zero draft.
  • the draft ratio of the fist drafting stage is usually lower than the draft ratio of the second drafting stage.
  • the insertion of the twist is held off is meant that the twist inserted in the drafted roving is prevented from running back to the exit of the, or the final, drafting stage by the further, substantially, zero draft, stage.
  • apparatus for manufacturing a yarn from a roving composed of staple fibers comprises means forming at least one drafting stage for the roving, twisting means operable to insert twist in the drafted roving, and means arranged to hold off the insertion of the twist and being operable to subject the drafted roving to a substantially zero draft and to wholly support the drafted material during its travel from the or the final drafting stage to where the twist is inserted in the drafted roving by the twisting means.
  • the apparatus preferably comprises two drafting stages formed by three sets of rolls, each set being formed of a nip roll and a drive roll, and which sets are rotatable at different speeds defined by the draft ratios required for the two drafting stages.
  • apron systems may be utilized in place of some or all of the sets of rolls.
  • an apron is meant a roller-driven, endless belt.
  • the twisting means may be, for example, in the form of a ring-and-traveller windup mechanism or one of other wellknown windup mechanisms which twist and collect the twisted drafted material, or yarn.
  • the means for holding off the twist is a single roll, or a nip roll/drive roll set, or a pair of aprons, positioned after the, or the final, drafting stage.
  • the rovings used to make the yarns according to the invention may be synthetic, manmade, or natural staple fibers, or mixtures thereof.
  • synthetic fibers are those made from polyesters and polyamides; examples of manmade fibers are cellulosic fibers; and examples of natural fibers are wool and cotton fibers.
  • the present invention is particularly applicable to the manufacture of staple-fiber yarns composed of cotton-type" staple fibers.
  • a cotton-type staple fiber is meant a fiber of the natural product or a synthetic staple fiber having a length which is substantially the same as that of the natural product.
  • the present invention provides a method of making a staple-fiber yarn from a roving composed of cotton-type, staple fibers, wherein the roving is drafted during its passage through two successive stages, one stage having a higher draft ratio than the other stage, the drafted roving is passed through a further stage having a length not greater than the effective staple length of the fibers in the roving and wherein the drafted roving is subjected to a substantially zero draft, and the drafted roving is twisted and collected in the form of a yam.
  • the first drafting stage has a draft ratio of the order l.5:l and the second drafting stage has a draft ratio of the order 22:1.
  • the invention further provides a drafting apparatus for making staple-fiber yarns from rovings composed of cottontype, staple fibers, which comprises means for supplying a roving, three sets of rolls, each set being composed of a nip roll and a drive roll therefor, which are arranged and adapted to operate at speeds in such a manner as to form two drafting stages, one having a higher draft ratio than the other, a fourth nip roll and a drive roll therefor arranged to form a third drafting stage with the third set of said three sets of rolls, which drafting stage has alength not greater than the effective staple length of the fibers in the roving, and being adapted to operate in such a manner that the fourth nip roll has a speed ratio of 1:1 with the third nip roll, and means for twisting and collecting the drafted roving asa yarn.
  • HO. 1 illustrates diagrammatically in side elevation one embodimertt of an apparatus according to the present invention
  • FIG. 2 is a similar illustration of a second embodiment of the apparatus.
  • FIG. 3 is a similar illustration of a third embodiment of the apparatus.
  • FIG. 4 is a similar illustration of a fourth embodiment of the apparatus.
  • one embodiment of an apparatus comprises three sets of rolls forming two drafting stages.
  • the first set comprises a nip roll 1 and a drive roll 2
  • the second set comprises a nip roll 3 and a drive roll 4
  • the third set comprises a nip roll 5 and a drive roll 6.
  • the speed ratio of the first and second sets of rolls is less than that of the second and third sets of rolls so that the second drafting stage has a higher draft ratio than the first drafting stage.
  • nip rolls 1, 3 and 5 are adjustably mounted on springs (not shown) whereby the nip pressures may be varied.
  • a further nip roll 7 is also mounted so as to be driven by the drive roll 6. Means are provided (not shown) for adjusting the pressure exerted by the nip roll 7 on the drive roll 6.
  • the apparatus is also provided with a ring-and-traveller windup mechanism 16.
  • a roving 8 composed of staple fibers is fed through the apparatus and is subjected to two drafting stages, one being between the sets of rolls 1,2 and 3,4 and the other between the sets 3,4 and 5,6.
  • the drafted roving issues from the nip between the nip roll 5 and the drive roll 6, i.e., the exit from the second drafting stage, and is supported by the surface of the roll 6 until it passes through the nip between the nip roll 7 and the drive roll 6.
  • the rolls 5, 6 and 7 are rotating at the same speed so that the further stage between the nips of rolls 5, 6 and 6, 7 has a substantially zero draft.
  • the length of the further stage is chosen to be not greater than the effective staple length of the fibers in the roving 8.
  • the drafted roving issuing from the rolls 6 and 7 is twisted into a yarn and is collected by the ring'and-traveller windup mechanism.
  • the twist inserted in the drafted roving runs along the drafted roving in a direction opposite to the latters movement.
  • the twist is, however, held off from reaching the exit of the second drafting stage by the nip roll 7 and the drive roll 6 of the further, zero draft, stage.
  • the nip roll 7 is replaced by a fourth set of rolls, comprising a nip roll 9 and a drive roll 10 which is arranged to be driven at the same speed as the rolls 5,6.
  • the distance between the nips of rolls 5, 6 and 9, 10 is chosen to be less than the effective staple length of the fibers in the roving 8, so that the majority of the fibers in the roving will at some instant during the travel of the roving 8 bridge the gap between the rolls 5, 6 and 9, 10.
  • the roving 8 is wholly supported during its travel through the further zero draft stage. Again, the twist inserted in the drafted roving was held off by the rolls 9, 10 from running back to the exit (i.e., the nip of the rolls 5,6) of the second drafting stage.
  • a twin-apron system is used.
  • the uppermost apron comprises a roll 12 and a guide ll about which a belt 13 is fitted
  • the lowermost apron comprises a roll 12a and a guide 110 about which a belt 131: is fitted
  • the roll 12a is a drive roll which drives the belt 13a.
  • the roll 12 is an idler roll which is driven by friction contact with the roll 12a.
  • the belt 13 is driven by the roll 12.
  • the speed of rotation of the drive roll 12a is synchronized with that of the drive roll 6 to provide a further zone having a substantially zero draft.
  • the distance between the nip of the rolls 5, 6 and the nip of the belts 13, 13a adjacent the guides 11, 11a is less than the effective staple length of the fibers in the roving 8, so that at any instant the gap between the nips is bridged by the majority of the staple fibers and the drafted roving can be considered to be wholly supported during its passage between the nips.
  • the drafted roving is carried through the remainder of the stage between the belts 13, 13a.
  • the twist inserted in the drafted roving is held off from the exit (i.e., the nip of the rolls 5, 6) of the second drafting stage by the nip between the belts 13, 13a adjacent the rolls 12, 12a.
  • the fourth embodiment illustrated in H6. 4 is a modification of the apparatus shown in H0. 1.
  • the rolls 3,4 are provided with endless belts 15, 15a and guides 14, 14a, respectively, to form a twin-apron system in the second drafting stage.
  • EXAMPLE I a A roving was prepared by plying 2X24 (246 tex) hank rovings of I00 percent Sudan Cotton staple fibers, the fiber lengths ranging from 0.38 inch to 1.63 inch.
  • the roving was processed using an apparatus as illustrated in FIG. 1 of the accompanying drawings but with the roll 7 removed.
  • the first drafting stage (x) had a draft ratio of about l.5:l and the second drafting stage (y) had a draft ratio of about 15.3: I giving a total draft of about 23.
  • the first drafting stage (x) was set at 2 inches and the second drafting stage (y) was varied from a setting at which no crackers were formed in the drafted roving to a setting in which processing became inoperable due to the continuous formation of crackers.
  • cracker formation EXAMPLE 2 a A roving was prepared from I00 percent wool fibers (64s Quality Bradford Tops), the fiber lengths ranging from 1.00 inch to 6.25 inches.
  • the roving was processed on an apparatus according to HO. 1, but which was modified by the removal of the rolls 3, 4 to provide a single drafting stage which was arranged tohave a draft ratio of 23: l.
  • the roll 7 was also removed.
  • the setting of the single drafting stage was varied from a setting at which no crackers were formed in the drafted roving to a setting in which processing became inoperable due to the continuous formation of crackers.
  • the first drafting stage (x) was set at,3 inches and the second drafting stage (y) was varied from a setting of 2.63 inches (i.e., greater than the effective staple fiber length) to 2.25 inches (i.e., less than the effective staple fiber length).
  • a roving was prepared from 3 denier, 100 percent nylon, The results Obtained from Examples 4(a) and are given variable length staple fibers produced from a tow processed Table on a Pacific converter cutter, giving fiber lengths, which 10 varied from 2.75 inches to 9 inches.
  • TABLE IV TABLE II Setting of Second The number ol'crackers and t heir Drafting Stage lengths in. per yd. of roving Setting of The number of crackers and t heir l5 Drafting Stage lengths in. per yd. of roving (inches)
  • Example 4(b) (inches) 2.63 2x013; 3x050; IXOJS; Nil
  • Example 2(a) Example 2(b) ZXI-O; lxz-o 5.5 Nil Nil 2.5 2x013; 2x0.25; 1X0.50;
  • Example b A similar roving was processed according to Example b.
  • Example 3(a) A similar roving was processed according to Example 3(a) but with the roll 7 being fitted to the apparatus.
  • the 5(a) and 5(b) are given in Table V. results obtained are given in Table III.
  • a roving weighing 45 drams/40 yards (2178 tex) was prepared from a blend of 55 percent by weight of 3 d.p.f. TERYLENE (R.T.M.) polyester staple fibers and 45 percent by weight of wool fibers.
  • the fibers in the blended roving had EXAMPLE 4 lengths which varied between 1.25 inches and 6.5 inches.
  • the apparatus used is that shown in FIG. 4 of the drawings for Examples 7(a) to 10(a), and without the roll 7 for Examples 7(b) to 10(b).
  • the drafting stages were set at 2.0 inches (first stage) and 1.7 inches (second) stage which are conventional settings for spinning rovings composed of 1.5 inch staple fibers.
  • the total draft used was 16.
  • EXAMPLE 1 1 Using the apparatus (a) as shown in FIG. 4, and (b) without the roll 7, TERYLENE polyester/cotton blend rovings (0.75 hank 788 tex) containing overlength" fibers were made into yarns.
  • the drafting stage settings were those used in examples 7 to 10, and the total draft ratio was 32.
  • the composition of each roving was 67% 2 d.p.f. X 1% inch TERYLENE polyester staple fibers, 33% Aloala cotton staple fibers, and 2% (based on the weight of the TERYLENE polyester/cotton fibers) of 2 d.p.f. X 2 inch TERYLENE polyester, overlength" staple fibers.
  • the distance between the nips of the rolls 5, 6 and the rolls 7, 6 was set at 0.75 inches.
  • the apparatus of the invention For the production of a high-quality yarn it is desirable to adjust the apparatus of the invention so that the drafted roving issuing from the exit of the final stage on its way to the windup mechanism does not contact a curved surface of a roll or belt. This ensures that the twist inserted in the drafted roving runs back to the exit of the final stage without running over a surface and hence the likelihood of faults occurring due to twist irregularities is minimized.
  • a method of manufacturing a yarn from a roving composed of staple fibers comprising passing the roving through at least one stage in which it is subjected to a drafting operation and twisting the drafted roving to form a yarn, wherein the insertion of the twist is held off bypassing the drafted roving through a further stage in which it is subjected to a substantially zero draft and is wholly supported during its travel therethrough.
  • the roving from which the yarn is made is composed of synthetic, manmade, or natural staple fibers, or mixtures thereof.
  • synthetic fibers include those made from polyesters and polyamides; manmade fibers include cellulosic fibers; and natural fibers include wool and cotton fibers.
  • a method of making a staple-fiber yarn from a roving composed of cotton-type, staple fibers wherein the roving is drafted during its passage through two successive stages, one stage having a higher draft ratio than the other stage, the drafted roving is passed through a further stage having a length not greater than the effective staple length of the fibers in the roving and wherein the drafted roving is subjected to a substantially zero draft, and the drafted roving is twisted and collected in the form of a yarn.
  • Apparatus for manufacturing a yarn from a roving composed of staple fibers comprising means forming at least one drafting stage for the roving, twisting means operable to insert twist in the drafted roving, and means arranged to hold off the insertion of the twist and being operable to subject the drafted roving to a substantially zero draft and to wholly support the drafted material during its travel from the or the final drafting stage to where the twist is inserted in the drafted roving by the twisting means.
  • Apparatus according to claim 7 comprising two drafting stages.
  • Apparatus according to claim 8 wherein the two drafting stages are formed by three sets of rolls, each set comprising a nip roll and a drive roll, and which sets are rotatable at different speeds defined by the draft ratios required for the two drafting stages.
  • Apparatus according to claim 7, wherein the means for holding off the twist is a single roll positioned after the final drafting stage.
  • twisting means is a ring-and-traveller windup mechanism.
  • Apparatus as in claim 7 wherein the means for holding off the twist is a nip roll/drive roll set positioned after the final drafting stage.
  • Apparatus as in claim 7 wherein the means for holding off the twist is a pair of aprons positioned after the final draft ing stage.
  • Apparatus for making staple-fiber yarns from rovings composed of cotton-type, staple fibers which comprises 5 means for supplying a roving, three sets of rolls, each set being composed of a nip roll and a drive roll therefor, which are arranged and adapted to operate at speeds in such a manner as to form two drafting stages, one having a higher draft ratio than the other, a fourth nip roll and a drive roll therefor arranged to form a third drafting stage with the third set of said three sets of rolls, which drafting stage has a length not greater than the effective staple length of the fibers in the roving, and

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Or Twisting Of Yarns (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
US869778A 1968-11-08 1969-10-27 Method and apparatus for making staple-fiber yarns Expired - Lifetime US3646745A (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4484435A (en) * 1980-07-16 1984-11-27 Maag Fritjof Method and device for the production of textile fibre yarns
US5950413A (en) * 1997-04-18 1999-09-14 Wellman, Inc. Spinning apparatus, method of producing yarns, and resulting yarns
US5970700A (en) * 1997-04-18 1999-10-26 Wellman, Inc. Drafting apparatus and method for producing yarns
WO2000003078A1 (en) 1998-07-09 2000-01-20 Wellman, Inc. Method of producing improved knit fabrics from blended fibers
US20080194164A1 (en) * 2005-02-17 2008-08-14 Werner Kandel Planar Textile Structure, Especially Tissue

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE900793C (de) * 1950-11-04 1954-01-04 Ver Jute Spinnereien Und Weber Verfahren und Vorrichtungen zum Verspinnen von Faserbaendern
US2728112A (en) * 1947-04-22 1955-12-27 Ralph C Berker Gill drawing frame
US2930085A (en) * 1954-06-30 1960-03-29 Skf Kugellagerfabriken Gmbh Textile drawing process and apparatus
US3051997A (en) * 1957-07-31 1962-09-04 Alsacienne Constr Meca Textile fiber drawing device
US3304584A (en) * 1964-10-07 1967-02-21 Maremont Corp Drafting mechanism
US3385045A (en) * 1965-06-16 1968-05-28 Slowiak Wladyslaw Ring spinning frame

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2728112A (en) * 1947-04-22 1955-12-27 Ralph C Berker Gill drawing frame
DE900793C (de) * 1950-11-04 1954-01-04 Ver Jute Spinnereien Und Weber Verfahren und Vorrichtungen zum Verspinnen von Faserbaendern
US2930085A (en) * 1954-06-30 1960-03-29 Skf Kugellagerfabriken Gmbh Textile drawing process and apparatus
US3051997A (en) * 1957-07-31 1962-09-04 Alsacienne Constr Meca Textile fiber drawing device
US3304584A (en) * 1964-10-07 1967-02-21 Maremont Corp Drafting mechanism
US3385045A (en) * 1965-06-16 1968-05-28 Slowiak Wladyslaw Ring spinning frame

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4484435A (en) * 1980-07-16 1984-11-27 Maag Fritjof Method and device for the production of textile fibre yarns
US5950413A (en) * 1997-04-18 1999-09-14 Wellman, Inc. Spinning apparatus, method of producing yarns, and resulting yarns
US5960621A (en) * 1997-04-18 1999-10-05 Wellman, Inc. Spinning apparatus, method of producing yarns, and resulting yarns
US5970700A (en) * 1997-04-18 1999-10-26 Wellman, Inc. Drafting apparatus and method for producing yarns
US6035621A (en) * 1997-04-18 2000-03-14 Wellman, Inc. Spinning apparatus, method of producing yarns, and resulting yarns
WO2000003078A1 (en) 1998-07-09 2000-01-20 Wellman, Inc. Method of producing improved knit fabrics from blended fibers
US20080194164A1 (en) * 2005-02-17 2008-08-14 Werner Kandel Planar Textile Structure, Especially Tissue

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ZA697528B (en) 1971-06-30

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