Classifications

• • 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
  • D01D5/12—Stretch-spinning methods
  • D01D5/16—Stretch-spinning methods using rollers, or like mechanical devices, e.g. snubbing pins
• • 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
  • D01D13/00—Complete machines for producing artificial threads
  • D01D13/02—Elements of machines in combination
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides

Definitions

• the present invention relates to the manufacture of fully drawn continuous multifilament nylon yarns and to a spinning machine used for the manufacture of these yarns and more particularly to a conversion process used to provide such a yarn spinning machine.
• Makers of continuous multifilament nylon yarns sell their product into apparel manufacturing markets where a mix of textured and untextured yarn is consumed. Untextured yarns are also called flat or fully drawn yarn.
• textured yarn is prepared from a feed yarn, a partially oriented yarn (POY) , by draw-twisting and heat setting.
• POY partially oriented yarn
• FOY fully drawn or fully oriented yarn
• the terms POY and FOY generally distinguish nylon yarns having an elongation to break of >60% and ⁇ 60% respectively; see "LOY MOY POY HOY FOY” by H. Treptow, Man-Made Fiber Year Book (CTI) 1986, page 6.
• the FOY process apparatus requires some means to draw or stretch the yarn.
• Some means to relax the fully drawn nylon yarn to allow good yarn package build in winding is necessary for high productivity.
• This yarn relax means may include a steam box as taught in Kemp at al . or a heated roll assembly.
• the makers of multifilament nylon yarns usually prepare both POY and FOY for various end uses .
• the spinning machine asset investment by each maker usually reflects the relative fraction of POY to FOY consumed by the apparel market into which the maker sells product.
• market demands shift over time as fashion trends may dictate a changing requirement for POY versus FOY consumed in the market.
• a fixed machine asset may present certain liabilities. While recognized as a long standing dilemma to the makers of POY and FOY nylon yarns, the ability to shift a POY spinning machine asset to a FOY spinning asset has not been addressed in the
• the present invention deals with this situation where a maker of nylon multifilament yarns must respond to a drop in the demand for textured apparel yarns (POY) and a corresponding growing requirement for fully drawn yarn (FOY) consumed in the market.
• POY textured apparel yarns
• FOY fully drawn yarn
• FIG. 1 A prior art godetless POY machine is shown in Figure 1. Such a prior art machine is readily converted to a FOY machine via the process of our invention. Our incentive to make this conversion resulted largely from space restrictions, both vertical and horizontal, imposed by traditional POY machine design. We have found productivity and investment criteria impose stringent design standards on facilities of POY machines. Often the yarn winding assemblies are less than 300 mm apart (on average) . Introducing a typical prior art feed and draw roll assembly to the midsection of closely spaced POY machines would result in undue complexity and be expensive. Moving the winder assemblies father apart to accommodate prior art feed and draw roll mechanisms and a yarn relax means is not a simple and economical option and would inhibit a readily reversible conversion of machines.
• the invention relates to a fully oriented yarn spinning machine for making a first and second plurality of fully oriented multifilament yarns, comprising: at least a first spinning assembly having a spin pack containing a spinneret plate for providing a plurality of filaments; a quench chimney for receiving and cooling the filaments; a finish applicator and convergence guide for receiving the filaments from the spinneret plate, for applying finish to the filaments, and for converging the filaments into a first and a second plurality of multifilament yarns; a first and a second alignment guide for receiving the first and second plurality of the multifilament yarns from the finish applicator and convergence guide; a first and a second stepped roll assembly for receiving the first and the second plurality of the multifilament yarns from the first and the second alignment guides, respectively, and for drawing the multifilament yarns to increase their length by a fixed amount; a steam relax unit between the first and the second unheated rotatable stepped feed and draw roll
• the fully oriented yarn spinning machine may optionally have an exit guide for maintaining the separation of the multifilament yarns within the steam relax unit and for directing the first and second plurality of the multifilament yarns.
• the invention further relates to a yarn spinning machine conversion process for converting a partially oriented yarn spinning machine to a fully oriented yarn spinning machine, the partially oriented yarn spinning machine having a first spinning assembly in a confined space between adjacent spinning assemblies, the process comprising: relocating and/or replacing a first and a second alignment guide for receiving a first and a second plurality of multifilament yarns; mounting in the confined space a first and a second unheated rotatable stepped feed and draw roll assembly for receiving the first and the second plurality of the multifilament yarns from the first and the second alignment guides, respectively, and for drawing the multifllament yarns to increase their length by a fixed amount; installing in the confined space a steam relax unit between the first and the second unheated rotatable stepped feed and draw roll assemblies, the steam relax unit for receiving the multifilament yarns from the unheated rotatable stepped feed and draw roll assemblies and for applying steam to the multifilament yarns to stabilize the multifilament
• the conversion process includes adding an exit guide for maintaining the separation of the multifilament yarns within the steam relax unit.
• Figure 1 is a schematic drawing of a plurality of prior art godetless POY spinning machines
• Figure 2a is a schematic drawing of a plurality of FOY spinning machines converted from those machines represented by the Figure 1 drawing;
• Figure 2b is a schematic drawing of a single FOY spinning machine mid-section
• Figure 2c is a schematic drawing of the single FOY machine mid-section as viewed from a right angle to Figure 2b;
• Figure 3a is a schematic drawing of one stepped feed and draw roll assembly relative to the steam relax chamber
• Figure 3b is a schematic drawing of an alternative embodiment, one stepped feed and draw roll assembly relative to the steam relax chamber with a yarn tension let-down step roll;
• Figure 4a and 4b are cut-away schematics drawings of the steam relax chamber at a right angle to one another.
• the invention is a fully oriented yarn (FOY) spinning machine and a yarn spinning machine conversion process for converting a partially oriented yarn (POY) spinning machine to the fully oriented yarn (FOY) spinning machine.
• the FOY spinning machine is for making a first and a second plurality of fully oriented multifilament yarns.
• the fully oriented yarn spinning machine comprises at least a first spinning assembly, but preferably comprises a plurality of substantially similar spinning assemblies in a row.
• Figure 2a depicts the first spinning assembly between a second spinning assembly and a third spinning assembly.
• the first, and preferably each, spinning assembly of Figure 2a has a spin pack (22) fed with molten polymer from polymer manifold (20) , a quench chimney (25) , a finish applicator and convergence guide (40) , a first and a second alignment guide (50) , a first and a second stepped roll assembly (90) , a steam relax unit (100) , an exit guide (116) , a first and a second pre wind-up guide (60) , and a first and a second windup assembly, not shown in Figure 2a, but illustrated positionally by the location of multiple yarn packages (70) wound on a spindle (72) .
• the spin pack (22) contains a spinneret plate for providing a plurality of filaments (30) .
• the quench chimney (25) is for receiving and cooling the filaments (30) .
• the finish applicator and convergence guide (40) is for receiving the filaments (30) from the spinneret plate, for applying finish to the filaments, and for converging the filaments into a first and a second plurality of multifilament yarns (80). There can therefore be 3, 4, 6,
• the first and the second alignment guides (50) are for receiving the first and the second plurality of the multifilament yarns (80) from the finish applicator and convergence guide (40) and for spacing the plurality of multifilament yarns prior to contacting the following roll surfaces .
• the first and a second stepped roll assemblies (90) shown in Figure 2a are for receiving the first and the second plurality of the multifilament yarns (80) from the first and the second alignment guides (50) , respectively, and for drawing the multifilament yarns to increase their length by a fixed amount.
• the first and the second unheated rotatable stepped feed and draw roll assemblies comprise a first feed roll (94b) , a second feed roll (94a) , a first draw roll (92a) and a second draw roll (92b) .
• the first feed roll (94a) and second feed rolls (94b) have first diameters (95) and the first and second draw rolls have second diameters (91) greater than the first diameters (95) .
• the first diameter (95) and the second diameter (91) are selected to provide a fixed draw ratio of the multifilament yarns.
• the first and second unheated rotatable stepped feed and draw roll assemblies are positioned vertically between each of the alignment guides (50) and the pre wind-up yarn guides (60) .
• the first feed rolls (94b) and the first draw rolls (92a) are positioned higher than the second draw rolls (92b) .
• the typical vertical distance between the alignment guide (50) and the pre wind-up guides (60) is 1400 mm, and the typical distance between the axes (96a) and (96b) of the two stepped rolls is about 400 mm.
• Axes of rotation (96a) (as shown in Figures 3a and
• the first feed roll (94b) , the second feed roll (94a) , the first draw roll (92a) and the second draw roll (92b) are adapted to rotate at the same speed with axes of rotation (96a, 96b) angled, by skew and tilt, to provide advancement of the multifilament yarns (80) , from the first feed roll (94b) , the second feed roll (94a) , the first draw roll (92a) and the second draw roll (92b) .
• each multifilament yarn end (80) typically wraps the feed rolls (94b, 94a) 1 and A times and wraps the draw rolls (92a, 92b) 2 and times.
• the first and the second unheated rotatable stepped feed and draw roll assemblies in each spinning assembly are mirror images of one another.
• each of the unheated rotatable stepped feed and draw roll assemblies is a double stepped roll assembly.
• a second roll step to smaller diameter on the outside helps to achieve better yarn relaxation, and hence better yarn package formation, by isolating the relax tension from the winding tension.
• each of the rotatable stepped feed and draw roll assemblies comprises a first feed roll (94b) , a second feed roll (94a) , a first draw roll (92a) , a second draw roll (92b) , a first relax roll (93b) and a second relax roll (93a) .
• the first and second feed rolls (94b, 94a) have a first diameter (95) and the first and second relax rolls (93b, 93a) have a second diameter (97a or 97b) greater than the first diameter (95) .
• the first feed roll (94b) , the second feed roll (94a) , the first draw roll (92a) , the second draw roll (92b) , the first relax roll (93b) and the second relax roll (93a) are adapted to rotate at the same speed with axes of rotation (96a, 96b) angled to provide advancement of the multifilament yarns (80) , from the first feed roll (94b) , the second feed roll (94a) , the first draw roll (92a) , the second draw roll (92b) , the first relax roll (93b) and the second relax roll (93a) and provide a preselected draw ratio of the multifilament yarns (80) and preselected amount of yarn relaxation prior to winding.
• the double sided steam relax unit (100) shown relative to the stepped roll assemblies, variously, in Figures 2a, 2b and 2c, receives the multifilament yarns (80) from the first and the second unheated rotatable stepped feed and draw roll assemblies and applies a steam atmosphere to the yarn.
• Steam which is introduced to the steam related unit at (102) as shown in Figure 2c, for example, promotes plasticity of the multifilament yarns (80) stabilizing the yarns and effecting tension relaxation of the yarn.
• the tension relaxation results in stable yarn package formation from lessened yarn retraction forces.
• the shared, or double sided, steam relax unit (100) is between the first and second unheated rotatable stepped feed and draw roll assemblies.
• the steam relax unit (100) is as close to the final contact of the yarns (80) with the draw rolls as possible to minimize the build up of tension from air drag before the steam relaxation since lower tension encourages more relaxation reducing subsequent retraction on the packages.
• the steam relax unit (100) is vertically between the first draw rolls (92a) and the second draw rolls (92b) .
• the steam relax unit (100) as viewed in Figure 4a includes a tube (106) through which steam enters leading to a chamber (104) having openings (108) .
• the steam relax unit (100) is adapted to cause steam to be applied to the multifilament yarns (80) with the multifilament yarns (80) at tensions at or below 0.2 grams per decitex at or about atmospheric pressure.
• the steam relax unit (100) has halves which are substantial mirror images of one another ( Figure 4a) . No internal jets or other guides are used; a double skinned cover (101) for insulation is provided.
• Slots (114c) communicating between yarn entrance slots (114a) and exit slots (114b) provide means to string-up the plurality of threadlines. Slots (114a) and (114b) serve further to vent steam to the atmosphere.
• An exit 20 guide (116) and pins (118) for maintaining the separation of the multifilament yarns (80) within the steam relax unit (100) and for directing the first and second plurality of the multifilament yarns (80) to pre wind-up guides (60) and to the winding unit (74) are the only guides associated with the steam relaxation unit (100) .
• the first and second pre wind-up guide (60) maintains the separation of the multifilament yarns (80) , fanning the first and second plurality of the multifllament yarns (80) .
• the first (74a) and the second (74b) windup assembly are for winding the first and the second plurality of the multifilament yarns (80) into a first and a second plurality of packages (70) .
• the first and the second windup assembly (72a, 72b) comprise a double deck windup assembly (74a, 74b) with yarn traversing means (76) for winding the multifilament yarns onto yarn cores mounted on spindle (75) into yarn packages (70) .
• the first and the second windup assemblies (74a, 74b) have a windup spindle or chuck (75) for winding the first and the second plurality of the multifilament yarns (80) into a first and second plurality of packages (70) .
• a horizontal distance (10) shown in Figure 2a) between axes of rotation of the windup chuck (72 or 75) in the first windup assembly (74a) in the first spinning assembly and the windup chuck (72 or 75) in the first windup assembly (74a) in the second and the third spinning assemblies is a maximum distance of less than or equal to 1000 mm and preferably less than or equal to 600 mm.
• the first and the second windup assemblies (74a, 74b) each include a traversing guide (76) for moving the first and the second plurality of the multifilament yarns (80) back and forth transverse to the multifilament yarns for winding the multifilament yarns on cores into the packages (70) .
• the spinning machines of the present invention are capable of spinning yarns of 10 to 250 decitex, of operating at 4,000 mpm to 6,000 mpm, in all melt spinning processes for fibers from all polyamides, especially nylon 6,6, nylon 6, nylon 6,10 and nylon 6,12 and polyesters, especially polyethylene terephthalate and polypropylene terephthalate .
• the invention is further directed to a yarn spinning machine conversion process for converting a partially oriented yarn spinning machine to the fully oriented yarn spinning machine.
• Illustrated schematically in Figure 1 is a plurality of partially oriented yarn spinning machines similar to those in wide commercial use that can be easily converted to the fully oriented yarn spinning machine of the present invention as shown in Figure 2a.
• the partially oriented yarn spinning machine is for making a first and a second plurality of partially oriented multifilament yarns.
• "partially oriented yarn” or POY means a yarn of greater than 60% elongation to break
• "fully oriented yarn” or FOY means a yarn of less than 60% elongation to break.
• the POY spinning machine comprises a plurality of substantially similar spinning assemblies in a row, including as illustrated in Figure 1 a first spinning assembly in a confined space between a second spinning assembly and a third spinning assembly.
• Each spinning assembly has a spin pack (22) , a quench chimney (25) , a finish applicator and convergence guide (40) , a first and a second alignment guide (50) , a first and a second pre windup guide (60) , and a first and a second windup assembly not shown, but in relative position to where a plurality of yarn packages (70) are wound on tube cores (72) .
• the yarn spinning machine conversion process for converting a POY spinning machine to a FOY spinning machine comprises the following steps in any order.
• the first and the second alignment guide (50) are relocated and/or replaced such that the relocated or replaced first and second alignment guides (50) , in Figure 2a are for receiving the first and the second plurality of multifilament yarns (80) and directing the multifilament yarns to the first and a second unheated rotatable stepped feed and draw roll assemblies (90) in Figure 2a.
• Guides (50) in Figure 2a now space out the threadlines to contact the feed roll surfaces individually.
• the first and the second unheated rotatable stepped feed and draw roll assemblies (90) are mounted in the confined space, essentially that space provided between neighboring machines and limited by the fixed difference (10) between the winding axes indicating by distance (10) .
• the first and a second unheated rotatable stepped feed and draw roll assemblies (94a, 94b and 92a, 92b) are for receiving the first and the second plurality of the multifilament yarns (80) from the first and the second alignment guides (50) , respectively, and for drawing the multifilament yarns (80) to increase their length by a fixed amount.
• the steam relax unit (100) is installed in the confined space between the first and the second unheated rotatable stepped feed and draw roll assemblies (90) .
• the steam relax unit (100) is for receiving the multifilament yarns (80) from the unheated rotatable stepped feed and draw roll assemblies (90) and for applying steam to the multifilament yarns (80) to stabilize the multifilament yarns (80) .
• the exit guide (116) is added immediately after the steam relax unit (100) for maintaining the separation of the multifilament yarns (80) within the steam relax unit (100) and for directing the first and second plurality of the multifilament yarns (80) to a first and a second windup assembly (74a and 74b) , respectively, for winding the first and the second plurality of the multifilament yarns (80) into a first and a second plurality of packages (70) .
• a maker of multifilament nylon yarns can convert a POY spinning machine asset base to a FOY machine asset base in response to market demand shifts in the relative fraction of the product, POY versus FOY.
• the conversion method of the present invention does not require winder relocation for spacing requirements and effectively and economically converts the typical POY machine to spin FOY yarns providing a novel apparatus. Further benefits are realized with the conversion process of our invention by reversibly performing such a conversion. A fiber maker can then "swing" between product types in response to market-demands .

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

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• 1996
  • 1996-11-27 GB GB9624683A patent/GB2319745B/en not_active Expired - Lifetime
• 1997
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  • 1997-11-25 WO PCT/US1997/021903 patent/WO1998023797A1/en active IP Right Grant
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• 1998
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