US3805342A

US3805342A - Method and apparatus for texturing yarn

Info

Publication number: US3805342A
Application number: US00281862A
Authority: US
Inventors: E Shattuck
Original assignee: Individual
Current assignee: Individual
Priority date: 1972-08-18
Filing date: 1972-08-18
Publication date: 1974-04-23
Anticipated expiration: 1991-04-23

Abstract

A permanent zig-zag crimp or helical configuration is imparted to a length of yarn, thread, tow or continuous filament textile material by extruding the length of yarn from a high pressure chamber, after which the yarn impinges on obstructing means for the imparting of the crimp. The length of yarn is held in the crimped state and heated in order to form a permanent set, followed by cooling of the strip of yarn. The extrusion opening in the high pressure chamber through which the yarn is extruded is substantially equal in cross-section to the cross-section of the yarn in order to achieve extrusion of the yarn from the high pressure chamber.

Description

United States Patent [191 [111 3,805,342 Shattuck 1 Apr. 23, 1974 METHOD AND APPARATUS FOR 3,626,557 12/1971 Chudgar et a1. ..28/1.3

TEXTURING YARN Primary Examiner--Louis K. Rimrodt [5 7] ABSTRACT A permanent zig-zag crimp or helical configuration is imparted to a length of yarn, thread, tow 0r continuous filament textile material by extruding the length of yarn from a high pressure chamber, after which the yarn impinges on obstructing means for the imparting of the crimp. The length of yarn is held in the crimped state and heated in order to form a permanent set, followed by cooling of the strip of yarn. The extrusion opening in the high pressure chamber through which the yarn is extruded is substantially equal in crosssection to the cross-section of the yarn in order to achieve extrusion of the yarn from the high pressure chamber.

16 Claims, 12 Drawing Figures FEES SUE/ZED Fl U/D .45 cooulva coou/w;

HEATING- HEATING PATENTEDAPR23 1974 sum 3 BF 4 .95 QQQU mm v v l I I I METHOD AND APPARATUS FOR TEXTURING YARN The present invention relates to the manufacture of yarn and more particularly to a method and apparatus for texturing yarn, or stated differently, for imparting a permanent zig-zag crimp or helical configuration in yarns, thread, tow or continuous filament textile materials.

In order to provide the desired bulkiness, soft texture, pleasing appearance and stretchiness to a fabric article, it has been found desirable in the production of the fabric articles comprising yarn made of natural or synthetic textile filaments and particularly those which are of the heat settable variety, to impart a permanent zig-zag, crimp, helical configuration, coils and the like to the filaments at some stage in their manufacture.

In the development of various techniques for texturingyarn, it was determined at an early stage that the process should be a continuous process, as contrasted to a batch process. The latter process involved expensive equipment which could handle only a limited amount of yarn, whereby the batch process was ex tremely expensive and time consuming.

Early efforts directed to a continuous process included the development of what is commonly known as a stuffer crimper in which a length of yarn is driven by a pair of rolls into a confined region so as to effectively stuff the length of yarn whereby crimping of the yarn occurs. Further efforts to refine a continuous texturing process resulted in the development of the aspirating technique wherein a length of yarn is contacted with a stream of fluid passing generally axially of the yarm to provide the driving force for the yarn. In a conventional aspirating apparatus the yarn would be passed through an orifice which was large enough to accommodate the yarn and a sufficient amount of air flow to effectively carry the yarn, with the size of the orifice being 8-10 times greater than the size of the yarn.

The present invention is directed to an entirely different concept for conveying thelength of yarn to an obstructing means whereat crimping is achieved. Fundamentally, the basic concept of the subject invention is to extrude a length of yarn through an extrusion opening provided in a pressurized container, with the extrusion being accomplished by means of the differential pressure between the high pressure container in which the yarn initially passes, and the atmospheric air pressure existing externally of the chamber when the yarn is crimped. Located in the immediate vicinity of the extrusion opening through which the yarn is extruded is a suitable obstruction means, somewhat akin to the stuffer crimper arrangement in the prior techniques, whereby the extruded yarn is allowed to zig-zag, coil, and generally twist and fold about itself in order to impart the desired texture to the yarn. The apparatus of the subject invention basically comprises a high pressure chamber having an extrusion opening substantially corresponding in cross-section to the crosssection of the yarn. The chamber is provided with a source of pressurized fluid. When the yarn is threaded through the extrusion opening, the chamber is substantially closed, except with respect to the fact that the yarn extending through the extrusion opening effectively defines the weakest point in the chamber, and when the chamber is filled with high pressure fluid, the differential pressure internally and externally of the chamber results in the development of an axial force in the yarn corresponding to the differential pressure internally and externally of the chamber multiplied by the cross-section of the opening. This unbalanced force gives rise to an axial driving force in the length of yarn, resulting in the yarn being effectively extruded from the chamber, and the axial force of the extruded yarn is sufficient to provide the necessary axial force for achieving texturing of the yarn when the latter im pinges upon an obstruction means located immediately downstream of the extrusion opening.

Fundamentally, the method of the subject invention for imparting a texture to a length of yarn comprises the steps of extruding a length of yarn from a pressurized container through an extrusion opening corresponding in cross-section to the cross-section of the yarn, and subsequently causing the yarn to impinge on an obstructing means disposed externally of the pressurized chamber in the vicinity of the opening. In order to establish a permanent set in the yarn, the additional steps of heating of the yarn and cooling of the yarn may be employed, or other steps depending on the composition of the yarn.

As is readily apparent, when the pressure within the chamber is maintained at a constant level, the axial driving force or extruding force acting on the yarn in order to extrude same from the container remains constant. This is particularly desirable in order to achieve uniform texturing of the yarn. In order to control the rate at which the yarn is extruded from the pressurized container, suitable metering rolls are provided within the container, and furthermore, where the obstruction means comprises a pair of drive rolls into the pins of which the extruded yarn impinges, suitable control means may be provided to coordinate the operation of the metering rolls within the pressurized container and the drive rolls defining the obstruction means of the apparatus.

Of extreme importance is the relationship between the diameter of the yarn and the extrusion opening in the pressurized container. Several techniques may be employed in order to meet the close fit required between the size of the yarn and the size of the extrusion opening in order to achieve the extruding force. In one embodiment, the extrusion is of a fixed diameter type, corresponding in cross-section to the cross-section of the yarn, whereas in another embodiment the extrusion opening is formed of two cooperating portions which are relatively movable in order to facilitate the initial threading of the yarn through the opening. In still additional embodiments, a flexible sealing means is employed in conjunction with the extrusion opening in order to insure a substantially air-tight relationship between the opening and the yarn, in which case a suitable seal is provided in the extrusion opening. The seal may be formed by means of high vicosity fluid in the area of the opening, with the yarn passing through the fluid and cooperating with the fluid in order to define a seal with the extrusion opening. In other embodiment, the seal between the extrusion opening and the yarn is defined by a flexible diaphragm having an opening corresponding to the cross-section of the yarn. With the latter configuration, the diaphragm would be sufficiently flexible such that a knot in the length of yarn could readily pass through the opening without causing an interruption in the continuous operation of the apparatus. In other embodiments, the extrusion opening in the pressurized container could be defined by a porous metal structure and additional means may be provided for pumping oil or other viscous fluid, under high pressure, through the porous metal so that a constant source of sealant material would be provided in the region of the opening to maintain the required air-tight seal between the yarn and the opening. In still another embodiment, a transverse opening is provided through the wall of the container leading to the extrusion opening, and pressurized oil or other sealant fluid is pumped into the region of the extrusion opening to maintain the continuous seal for insuring the extrusion operation of the subject texturing process.

Accordingly, it is an object of the subject invention to provide anew and improved method and apparatus for texturing yarn, and more particularly, a new and improved method and apparatus which employs the unique concept of extruding yarn in order to impart thereto the necessary axial force for achieving crimping/texturing of the yarn.

Further objects and advantages of the invention will appear from the following detailed description, taken in conjunction with the following drawings in which:

FIG. 1 is a schematic illustration of a first embodiment of the texturing apparatus of the subject invention;

FIG. 2 is a sectional view taken along 2-2 in FIG. 1;

FIG. 3 is a detailed sectional view of the extrusion opening of an apparatus according to the subject invention, and including a schematic representation of the pressure forces acting within the pressurized container;

FIG. 4 illustrates a second embodiment of the texturing apparatus according to the subject invention;

FIG. 5 illustrates a third embodiment of the texturing apparatus according to the subject invention;

FIG. 6 illustrates an arrangement of heating rolls for pre-heating the length of yarn prior to the extrusion operation;

FIG. 7 illustrates a fourth embodiment of the texturing apparatus made according to the subject invention; and

FIGS. 812 illustrate alternative constructions for the extrusion opening of the subject invention.

Before describing in detail the several embodiments of the subject invention, it should be understood that the term yarn as used herein is intended to apply not only to fiber assemblies (whether natural or manmade) spun from staple-length fibers, but also to such assemblies comprised of continuous filaments; blends of staple-length fibers and continuous filaments; and to yarns consisting of a single ply or several twisted or untwisted plies.

Referring to FIG. 1, a first embodiment of the apparatus made according to the subject invention basically comprises an air-tight chamber or container 10 having an inlet conduit 12 for receiving pressurized fluid such as air, gas, or steam. The pressurized fluid is at a pressure greater than 100 p.s.i.g. in order to develop sufficient extrusion force for crimping the yarn. In addition, the chamber 10 has an extrusion opening 14. Of primary importance is the size of the extrusion opening 14 relative to the length of yarn Y to be textured, and more particularly, the cross-section of the extrusion opening 14 must be substantially equal in size to the cross-section of the yarn Y to be textured. The latter is fed from a pirn 16 over

roller guides

18,18 through a tension disc 20 and through a yarn inlet opening 22 formed in the chamber 10. As the yarn Y passes through the interior of the chamber 10 it is metered by means of

metering rolls

24,24 prior to reaching the extrusion opening 14. The metering rolls also function to prevent the yarn from being driven or extruded out of the chamber 10 through the inlet opening 22.

Located immediately outside of the chamber 10 is the vicinity of the extrusion opening 14 is an obstructing means 30 wherein crimping of the yarn is achieved. In the embodiment shown in FIG. 1, the obstruction means is defined at the nip of a roller 32 and a continuous belt 34 driven by

rollers

36,36. As more distinctly illustrated in FIG. 2, roller 32 has a peripheral groove 32a therein for accomodating the length of crimped yarn as it leaves the nip of the belt 34 and roller 32 which defines the obstruction means. The crimp or textured yarn, designated by the numeral 40 is then passed over roller guide 42 to a take-up pirn 44 or collection means (now shown) for further processing into a fabric article.

The

metering rolls

24,24 within the chamber 10 are interconnected with the obstruction means, and in particular the roll 32 by suitable coordinating means (schematically illustrated in FIG. 1 by dotted line 46) so as to insure that the metering of the yarn Y from the chamber 10 is coordinated with the collection of the textured yarn, and, by this coordination to control the rate, type and degree of crimping that occurs at the obstruction means 30.

In the operation of the apparatus, the yarn is threaded from the pirn 16 over the guide rollers 18 and the alignment funnel 20 through the yarn entrance opening 22 into the chamber 10, through the

metering rolls

24,24 and thence through the extrusion opening 14. As indicated previously, the cross-section of the extrusion opening substantially corresponds to the corsssection of the yarn in order to insure the proper operation of the subject apparatus. In order to obtain an understanding of how the extrusion of the yarn is achieved by the subject apparatus, reference is made to FIG. 3 which provides a detailed sectional view of an extrusion opening 14 provided in a pressurized chamber 10, and having a continuous length of yarn Y extending therethrough. The chamber 10 is pressurized and the pressure forces which are uniformly distributed within the chamber 10 are indicated by the arrows P. As is readily apparent, equal and opposite pressure forces exist on opposite sides of the yarn, except for an unbalanced pressure force F,, which exists across an imaginary plane, designated by the letter C, extending across the cross-section of the strip of yarn Y. The exterior of the chamber 10 is at atmospheric pressure P, whereby an opposite axial force F exists in the yarn as a result of the atmospheric pressure acting across a similar cross-section of the yarn, designated by C. Since the pressure force F within the chamber is greater than the atmospheric pressure force F, and since the crosssection of the yarn is identical within and without of the chamber 10, there is an unbalanced force (corresponding to the difference in magnitude between F and F acting on the yarn in an axial direction causing the yarn to be extruded from the pressurized container toward the obstruction means.

As the yarn leaves the extrusion opening 14 of the pressurized chamber 10, it impinges upon the obstruction means 30 defined at the nip of the belt and roller, and at such point folds over upon itself and zig-zags, crimps, or folds to a helical configuration so as to result in texturing of the yarn. If desired, the roller 32 may be heated so as to form a permanent set in the yarn, with the heating means for the roller 32 being schematically designated by numeral 48.

In summary, the method of the subject invention comprises the first step of extruding a length of yarn Y from the pressurized container through the extrusion opening 14 whose cross-section closely approximates the cross-section of the yarn, followed by the step of causing the yarn to impinge on the obstructing means 30 in order to texture the yarn. Additional steps of heating the yarn, as well as cooling the yarn may be added to the process.

A second embodiment of the subject apparatus is illustrated in FIG. 4 wherein like numbers designate similar structure as found in the preferred embodiment illustrated in FIG. 1. Accordingly, the apparatus of the second embodiment includes a pressurized chamber 10 provided with an inlet 12 for pressurized fluid, a pair of metering rolls 24,24, a yarn entrance opening 22 provided in the chamber 10, and an obstruction means defined between the nip of a pair of

rolls

50,50. The obstruction rolls 50,50 are interconnected with the metering rolls 24,24 by suitable interconnection linkages 46 so as to coordinate the operation of the apparatus, and more particularly to coordinate the rate at which the yarn is extruded from the pressurized chamber and the rate at which the packed mass of crimped yarn is carried along by the obstruction means. Dowstream of the

obstruction rollers

50,50 there is provided a tube 52 through which the yarn is guided. The first portion of the tube 52 through which the textured yarn 40 is conducted is heated by heating means 54,54 so as to form a set in the textured yarn 40 while the opposite end of the plates are surrounded by cooling means 56,56 in order to permanently set the textured yarn 40.

Referring now to FIG. 5, a third embodiment of the subject apparatus is characterized by the pressurized chamber 10 being of sufficient size to accommodate the pirn 16 whereby a yarn entrance opening is not required. Asin the previous embodiments the extrusion opening 14 corresponds in size to the size of the yarn and the metering rolls 24,24 are interconnected with the rollers 60 for the belt driven obstruction means 30. The latter include heating means 64,64 and cooling means 66,66 which operate to respectively set and per manently condition the textured yarn prior to being collected onto pirn 44.

FIG. 6 illustrates an arrangement of a pair of

rollers

70,70 which may be used in lieu of the metering rolls 24 within the pressurized chamber 10. One or both of the

rollers

70,70 may be heated for pre-heating of the yarn prior to extrusion, and the arrangement of wrapping the yarn Y several times around the

rollers

70,70 enables metering of the yarn from the chamber 10.

Alternatively, the pressurized fluid input through inlet conduit 12 to the chamber 10 may be steam or hot air in order to preheat the yarn Y prior to extrusion and crimping.

Referring now to FIG. 7, a fourth embodiment of the subject apparatus is illustrated wherein the obstruction means 30 takes the form of a roller driven porous belt 80, the underside of which is subject to a vacuum as designated at 82, whereby as the yarn Y leaves the extrusion opening 14 it immediately contacts the porous belt 80, and the momentum of the yarn impringing onto the previously packed mass causes crimping and the vacuum created below the porous belt causes the packed mass of yarn to stay on the moving belt past the source of heat, for example, an infrared lamp 84 which heat sets the yarn to a permanent textured condition. Next, the yarn is pulled off the belt to be wound on a pirn or other collection means for further processing into fabric articles.

FIGS. 8 through 12 designate various alternative constructions of the extrusion opening 14 in order to ensure the sufficiently close fit between the size of the yarn and the size of the extrusion opening to achieve the extrusion effect previously described. It might be noted that the extrusion effect is generally similar to that which occurs in a bullet fired from a rifle. The bullet constitutes an obstruction in the bore of the rifle, and the differential pressure acting on opposite ends of the bullet results in a force which is directly proportional to the cross-section of the bullet, and this force effectively extrudes the bullet from the bore in a manner similar to the extrusion process of the subject invention. This is to be contrasted with the prior art techniques wherein the axial air flow of the aspirating devices is effective in carrying along and operating along the cross-sectional periphery of the yarn so as to provide the axial driving force for the yarn.

As is readily apparent, one of the primary considerations in the construction of the extrusion opening is to insure that the yarn effectively forms a substantially airtight seal with the extrusion opening. In order to enhance the seal, one possible construction of the extrusion opening is illustrated in FIG. 8 wherein the extrusion opening 14 in the pressurized container 10 is somewhat greater in size than the cross-section of the yarn Y, and in order to provide an effective seal, oil or other highly viscous fluid is provided in the vicinity of the extrusion opening 14. The oil or other highly viscous fluid 90 acts as a seal between the yarn Y and the structural wall of the opening 14, and since the oil is flexible, in the event that the yarn has a knot or slub Y, in it, the knot or slub can readily pass through the extrusion opening in a smooth, continuous flow rather than causing a temporary interruption in the processing of the yarn.

In FIG. 9, the extrusion opening 14 may be formed by means of a porous metal plug having an orifice therein, which porous metal would be permanently secured to the pressurized container 10. Along the periphery of the plug 100 there is provided a manifold 102 which is supplied with a source of oil 104 or other fluid under high pressure. As in the: case of FIG. 8, the extrusion opening defined in the porous metal would be slightly larger than the size of the yarn Y whereby slubs or knots Y could readily pass therethrough. In order to form an effective seal, the oil or other fluid under high pressure would be pumped through the manifold 102 and forced through the porous metal 100-so as to constantly provide a fluid seal in the extrusion opening 14.

FIG. 10 provides still another construction of the extrusion opening in that the opening would be of slightly greater size than the cross-section of the yarn, and a transverse opening 108 would be provided in the wall of the pressurized container 10 so that oil 110 or other fluid under pressure may be constantly applied to the vicinity of the extrusion opening 14 to maintain an effective fluid seal therein and lubricate the opening 108.

FIG. 11 illustrates another construction of the extrusion opening in which the opening would be defined by a flexible diaphragm 110 having an orifice 112, corresponding generally in size to the cross-section of the yarn. In addition a body of oil or other highly viscous fluid may be provided in the vicinity of the extrusion opening to maintain a constant air-tight seal across the extrusion opening, and the combination of the flexible diaphragm 110 and oil ensures that even if a know or slub Y, were required to be passed through the extrusion opening, no discontinuity in the operation of the apparatus would be required.

FIG. 12 illustrates still another form of extrusion opening 14, and one which is particularly advantageous during the initial setting up of the subject apparatus. The extrusion opening is defined by two cooperating sections 120 of the container 10, each section 120 being pivotally attached to the pressurized contained by hinge 122. By this arrangement, with the sections 120 rotated to the inoperative positions (shown in dotted lines) the yarn Y may be readily threaded into the cut-out 124 in a section 120 and then the sections are rotated ot the operative positions (shown in solid lines) thereby completing the threading operation.

As previously noted, for some yarn materials, preheating of the yarn prior to crimping may be desirable. In such cases, preheating may be effected either before the yarn enters the chamer or while the yarn is in the chamber. As is readily apparent, the invention thus conceived is suspectible to various modifications, alternations and changes, all of which are to be considered as included within the scope of the invention as defined by the appended claims.

What is claimed is:

1. Apparatus for imparting a texture to yarn comprising a chamber having an opening substantially corresponding in cross-section to the cross-section of said yarn, a source of pressurized fluid in communication with said chamber, and obstruction means disposed adjacent said opening externally of the chamber in ambient air whereby when said yarn is threaded through said opening and pressurized fluid is provided in said chamher, the yarn is extruded from the chamber and impinges on said obstructing means resulting in texturing of the yarn.

2. Apparatus for imparting a texture to yarn as in claim 1 further including means for heating said textured yarn, and means for cooling said textured yarn.

3. Apparatus for imparting a texture to a length of yarn as in claim 1 wherein the pressurized fluid is steam.

4. Apparatus for imparting a texture to yarn as in claim 1 further including metering rolls disposed in said chamber, said yarn being passed through the nip of said metering rolls prior to being threaded through said opening.

5. Apparatus for imparting a texture to yarn as in claim 1 wherein the fluid pressure within the chamber is greater than 100 p.s.i.g.

6. Apparatus for imparting a texture to yarn as in claim 1 further including a pair of metering rolls disposed in said chamber for metering the yarn prior to its extrusion from the chamber, and further including a pair of crimping rolls disposed externally of the chamber, the nips of said crimping rolls defining the obstruction means, and means for coordinating the rotating of said metering rolls and said crimping rolls.

7. Apparatus for imparting a texture to yarn as in claim 1 wherein said chamber is provided with a second opening, said second opening substantially corresponding in cross-section to the cross-section of said yarn, which yarn is, in turn, threaded through said second opening, through said pressurized chamber, and through said first extrusion opening.

8. Apparatus for imparting a texture to yarn as in claim 1 wherein said pressurized fluid is air.

9. Apparatus for imparting a texture to yarn as in claim 1 wherein said obstruction means comprises of a pair of spaced, roller mounted belts, and further including heating means and cooling means disposed in the vicinity of said belts in order to successively heat and cool the textured yarn passing therethrough.

10. Apparatus for imparting a texture to yarn as in claim 1 wherein said chamber includes two relatively moveable portions thereof defining the opening corresponding in cross-section to the cross-section of said yarn.

11. Apparatus for imparting a texture to yarn as in claim 1 wherein the obstruction comprises a roller driven porous belt, the outside surface of said belt receiving the yarn extruded from said opening, while the inside surface of said belt is in communication with a source of reduced pressure, and further including heating means for heating said crimped yarn to permanently set same.

12. Apparatus for imparting a texture to yarn as in claim 1 wherein a high viscous fluid is provided in the region of said extrusion opening to define an air-tight seal therewith through which said yarn is extruded.

13. Apparatus for imparting a texture to yarn as in claim 1 wherein said opening is defined by a porous metal plug fixedly secured in the wall of said chamber, which plug includes an opening through which the yarn is threaded, said plug further including a peripherial manifold which is in communication with a source of high pressure fluid, which fluid passes through the porous metal plug to the vicinity of said opening in the plug for forming an air-tight seal through which the yarn is extruded.

14. Apparatus for imparting a texture to yarn as in claim 1 wherein said pressurized chamber includes a transverse opening extending transverse to the longitudinal axis of said opening, and a source of pressurized fluid in communication with said transverse opening so as to provide a continuous source of pressurized high viscous fluid to the opening for forming an air-tight seal through which said yarn is passed.

15. A method of imparting a texture to yarn comprising the steps of:

extruding said yarn from a pressurized contain to ambient air through an opening therein corresponding in cross-section to the crosssection of said yarn; and

causing said yarn to impinge on an obstructing means in ambient air disposed externally of said pressuirzed chamber in the vicinity of said opening.

16. A method for imparting a texture to a length of yarn as in claim 15 further including the steps of:

heating said yarn to form a permanent set in the yarn;

and

cooling said yarn.

Claims

1. Apparatus for imparting a texture to yarn comprising a chamber having an opening substantially corresponding in crosssection to the cross-section of said yarn, a source of pressurized fluid in communication with said chamber, and obstruction means disposed adjacent said opening externally of the chamber in ambient air whereby when said yarn is threaded through said opening and pressurized fluid is provided in said chamber, the yarn is extruded from the chamber and impinges on said obstructing means resulting in texturing of the yarn.

15. A method of imparting a texture to yarn comprising the steps of: extruding said yarn from a pressurized contain to ambient air through an opening therein corresponding in cross-section to the cross-section of said yarn; and causing said yarn to impinge on an obstructing means in ambient air disposed externally of said pressuirzed chamber in the vicinity of said opening.

16. A method for imparting a texture to a length of yarn as in claim 15 further including the steps of: heating said yarn to form a permanent set in the yarn; and cooling said yarn.