WO2023111758A1 - Systèmes et procédés de production d'un faisceau de filaments et/ou d'un fil - Google Patents

Systèmes et procédés de production d'un faisceau de filaments et/ou d'un fil Download PDF

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Publication number
WO2023111758A1
WO2023111758A1 PCT/IB2022/061694 IB2022061694W WO2023111758A1 WO 2023111758 A1 WO2023111758 A1 WO 2023111758A1 IB 2022061694 W IB2022061694 W IB 2022061694W WO 2023111758 A1 WO2023111758 A1 WO 2023111758A1
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WO
WIPO (PCT)
Prior art keywords
filaments
polymer
spin
luster
dyes
Prior art date
Application number
PCT/IB2022/061694
Other languages
English (en)
Inventor
Anthony CASCIO
James Mason
Daniel Amos
Lucinda Jones
Margaret Archelle BAILEY
Michael Christopher Gallman
Jeffrey Frank MERRICK
Garnett Anson WATKINS, Jr.
Original Assignee
Aladdin Manufacturing Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Aladdin Manufacturing Corporation filed Critical Aladdin Manufacturing Corporation
Publication of WO2023111758A1 publication Critical patent/WO2023111758A1/fr

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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
    • D01D5/08—Melt spinning methods
    • 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
    • D01D1/00—Treatment of filament-forming or like material
    • D01D1/06—Feeding liquid to the spinning head
    • D01D1/09—Control of pressure, temperature or feeding rate
    • 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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/24—Bulked yarns or threads, e.g. formed from staple fibre components with different relaxation characteristics
    • 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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
    • 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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics

Definitions

  • FIG. 1 illustrates a schematic diagram of a system according to one implementation.
  • FIG. 2 illustrates a schematic diagram of a system according to another implementation.
  • FIG. 3 A illustrates a schematic diagram of a spinning system according to another implementation.
  • FIG. 3B illustrates a schematic diagram of optional post-spinning processes for the spinning system in FIG. 3 A.
  • each spin station also includes at least one manifold (static or dynamic) and at least one mixing plate wherein each mixing plate defines at least one channel.
  • the at least one mixing plate is disposed between the at least one manifold and the at least one spinneret.
  • the polymer of one or more of the N extruders may comprise a thermoplastic polymer.
  • thermoplastic polymers that may be used for the filaments named in any of the first through seventh aspects include polyamides, polyesters, and/or polyolefins.
  • a polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.
  • the polyamide may have been formed by condensation polymerization of an amino acid (such as 11- aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or co-aminolauric acid).
  • an amino acid such as 11- aminoundecanoic acid
  • a lactam such as caprolactam or co-aminolauric acid
  • polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 61, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.
  • aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 61
  • polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), polyethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentam ethylene sebacate), poly(hexam ethylene sebacate), poly( 1,4- cy cl ohexylene terephthalate), poly(l,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).
  • PET poly(ethylene terephthalate)
  • PTT poly(trimethylene terephthalate)
  • the resulting bundles may comprise from 0-50% of the first polymer, from 0-50% of the second polymer, and from 0-50% of the third polymer.
  • the filaments comprising the first polymer may be 50% of the filaments in the bundle
  • the filaments comprising the second polymer may be 25% of the filaments in the bundle
  • the filaments comprising the third polymer may be 25% of the filaments in the bundle.
  • the filaments in the first, second, and third bundle can respectively, in %, be 10: 10:80, 10:20:70, 10:30:60, 10:40:50, 20: 10:70, 20:20:60, 20:30:50, 20:40:40, 30: 10:60, 30:20:50, 30:30:40, 40: 10:50, 40:20:40, 40:30:30, and the like.
  • the volumetric flow rate can be adjusted by the processor such that the resulting bundles comprise from 0-100% of the first polymer and from 0-100% of the second polymer.
  • the resulting bundle may comprise from 0-75% of the first polymer and from 0-75% of the second polymer.
  • the resulting bundle may comprise 50% of the first polymer and 50% of the second polymer.
  • the polymer of the filaments may be solution dyed polymer.
  • the solution dyed polymer filaments are space dyed after processing (also referred to as “over dying”). And, in other implementations, the filaments are not solution dyed and are space dyed or dyed regularly after processing.
  • a solution dyed polymer has a coloring agent added to the polymer prior to filament formation out of the spinneret.
  • a space dyed polymer has a coloring agent that is added to the filament after formation out of the spinneret.
  • Dyability characteristic refers to a filament’s affinity to absorb a dye under the same processing conditions.
  • non-solution-dyed filaments may appear white after spinning due to the lack of presence of dye molecules, pigments, or other molecules that would provide a different color than the material substrate.
  • a dyeing process for example PET using disperse dyes, a molten stream formed with a deep dye PET would have a darker color saturation than a molten stream produced with a traditional PET.
  • the first polymer comprises one or more polyamide polymers.
  • a polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.
  • the polyamide may have been formed by condensation polymerization of an amino acid (such as 11- aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or co-aminolauric acid).
  • an amino acid such as 11- aminoundecanoic acid
  • a lactam such as caprolactam or co-aminolauric acid
  • polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 61, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.
  • aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 61
  • the first polymer comprises polyamide 6,6. In other particular embodiments, the first polymer comprises polyamide 6.
  • the polyamide polymer can absorb a first dye.
  • the first dye comprises one or more acid dyes.
  • Acid dyes are water-soluble anionic dyes that are applied to fibers using neutral to acid dye baths. Attachment to the fiber is attributed, at least partially, to salt formation between anionic groups in the dyes and cationic groups in the fiber.
  • the acid dye may be chosen from a leveling acid dye, a milling dye, or a metal complex acid dye.
  • the acid dye is chosen from an anthraquinone type due, an azo dye, or a triarylmethane dye.
  • Acid dyes which may be used in the present disclosure include, but are not limited to, Acid Yellow 7, Acid Yellow 17, Acid Yellow 23, Acid Yellow 34, Acid Yellow 36, Acid Yellow 40, Acid Yellow 42, Acid Yellow 49, Acid Yellow 73, Acid Yellow 99, Acid Yellow 127, Acid Yellow 129, Acid Yellow 151 Acid Orange 3, Acid Orange 7, Acid Orange 8, Acid Orange 10, Acid Orange 24, Acid Orange 52, Acid Orange 60, Acid Orange 74, Acid Orange 116, Acid Orange 156, Acid Red 1, Acid Red 4, Acid Red 14, Acid Red 50, Acid Red 52, Acid Red 73, Acid Red 87, Acid Red 88, Acid Red 92, Acid Red 94, Acid Red 99, Acid Red 114, Acid Red 119, Acid Red 131, Acid Red 151, Acid Red 249, Acid Red 266, Acid Red 299, Acid Violet 19, Acid Violet 43, Acid Violet 48, Acid Violet 49, Acid Violet 90, Acid Green 1, Acid Green 3, Acid Green 9, Acid Green 16, Acid Green 20, Acid Green 25, Acid Green 92, Acid Violet 90, Acid Green 1, Acid Green 3, Acid Green 9, Acid Green 16, Acid Green 20, Acid Green 25, Acid
  • Typical polyesters as used in the present disclosure may be formed by condensation of a dicarboxylic acid and a diol.
  • dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4’ -diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-napthalene dicarboxylic acid, phthalic acid, 4,4’ -methyl enebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3 -methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11 -undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid
  • polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), polyethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentam ethylene sebacate), poly(hexam ethylene sebacate), poly( 1,4- cy cl ohexylene terephthalate), poly(l,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).
  • PET poly(ethylene terephthalate)
  • PTT poly(trimethylene terephthalate)
  • the second polymer comprises polyethylene terephthalate.
  • the second, polyester polymers can absorb a second dye.
  • the second polymers cannot absorb the first dye.
  • the second dye comprises one or more disperse dyes.
  • Disperse dyes have low solubility in water, typically less than 1 mg/L, and are applied to the fibers as an extremely fine suspension. Upon attachment, the particles dissolve, and owing to their low molecular weight, migrate throughout. Disperse dyes are typically azo dyes or anthroquinone dyes.
  • the first polymer comprises a polyamide
  • the second polymer comprises a PTT
  • the third polymer comprises a PTT.
  • the polyamide polymer absorbs an acid dye but the PTT does not, which leaves the PTT undyed in response to an acid dye being applied to the bundle of filaments comprising the polyamide and PTT polymers.
  • a disperse dye may be applied to a bundle of filaments comprising the polyamide and PTT polymers, which is absorbed by both polymers but at different levels, providing tonal or chromatic differences.
  • An acid dye may also be applied to this bundle of filaments, which would be absorbed by only the polyamide filaments and could lead to further tonal or chromatic differences.
  • the dye level of the first, second, and/or third polymer may be different from each other.
  • the first polymer may have an affinity for dyes having a bright deep shade
  • the second polymer may have an affinity for dyes having a light dye shade
  • the third polymer may have an affinity for cationic dyes. Accordingly, bundles may be produced containing tonal and chromatic differences.
  • the first luster type may be clear, bright, dull, semi-dull, extra dull, or super dull
  • the second luster type may be clear, bright, dull, semi-dull, extra dull, or super dull, wherein the first luster type and second luster type are different.
  • a third extruder comprising a third polymer having a third luster type may be included.
  • the third luster type is different than the first luster type and the second luster type.
  • the system may produce a bundle of filaments exhibiting a luster effect that is varied along the length of the bundle of filaments and/or within a radial cross section of the bundle of filaments.
  • the first luster type may be full dull
  • the second luster type may be semi dull
  • the third luster type may be full bright. Accordingly, the resulting bundle of filaments will contain a unique color perception compared to a bundle of filaments containing a single luster type.
  • Various combinations of the first, second, and optionally third luster types are included in the present disclosure.
  • the processor 110 is configured to execute computer readable instructions that cause the processor 110 to adjust the volumetric flow rate of the polymer pumped by each spin pump 104a-c to achieve a ratio of the polymers to be included in the filaments 114 spun from the spinneret 108. Adjusting the volumetric flow rate of the polymer extruded from each of the extruders 102a, 102b, 102c adjusts the ratio of the polymers in the filaments 114, which changes the overall color, hue, luster, and/or dyability characteristic of the bundle of filaments 114 spun through the spinneret 108.
  • the ratio of the polymers to be included in the filaments 114 refers to the ratio of colors, hues, lusters, and/or dyability characteristics from each extruder that are included in the bundle of the filaments 114.
  • the colors, hues, lusters, and/or dyability characteristics of the spun filaments 114 may include filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the first extruder 102a, filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the second extruder 102b, filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the third extruder 102c, and/or filaments having a color, hue, luster, and/or dyability characteristic that is a mixture of the colors, hues, lusters, and/or dyability characteristics from the extruders 102a, 102b, 102c.
  • the filaments 114 may include a first group of filaments that have the color, hue, luster, and/or dyability characteristic of the polymer from the first extruder 102a, a second group of filaments that have the color, hue, luster, and/or dyability characteristic of the polymer from the second extruder 102b, a third group of filaments that have the color, hue, luster, and/or dyability characteristic of the polymer from the third extruder 102c, and/or a fourth group of filaments that have a color, hue, luster, and/or dyability characteristic that is a mixture of the colors, hues, lusters, and/or dyability characteristics from the extruders 102a, 102b, and/or 102c.
  • At least a portion of the filaments in the fourth group may have a color, hue, luster, and/or dyability characteristic that is a mixture of two or more colors, hues, lusters, and/or dyability characteristics of the streams.
  • at least a portion of the filaments in the fourth group may have different colors, hues, lusters, and/or dyability characteristics along different portions of a length of the filament and/or within a radial cross section of at least one filament within each of the portions along the length of the filament.
  • a first portion of a length of a filament may have a first color and a second portion of the length of the filament may have a second color.
  • a portion of the length of the filament may have a color that is a mixture of two or more colors.
  • a radial cross section of a filament through one portion of the length of the filament may have two or more different colors than the radial cross section of the filament at another portion of the length of the filament.
  • This system 100 allows for filaments to be made having more colors, hues, lusters, and/or dyability characteristics than the number of extruders providing each color, hue, luster, and/or dyability characteristic. For example, if the extruders 102a-102c each have polymers solution dyed red, blue, and yellow, various ratios of these polymers yield filaments having these colors and combinations thereof, such as purple, orange, and green.
  • the speed of each spin pump 104a- 104c is at least 2 RPM. And, in certain implementations, a maximum speed of each spin pump 104a- 104c is 30 RPM. However, in other implementations, the maximum speed of each spin pump may be higher. If other process controls are the same, increasing the RPM of the spin pump 104a-104c increases the linear density, or titer (e.g., also referred to as “denier per filamenf ‘, “denier per fiber” or “DPF”)) per filament.
  • titer e.g., also referred to as “denier per filamenf ‘, “denier per fiber” or “DPF”
  • the average denier of each bundle of filaments can be increased or decreased by changing the speed of the pumps.
  • the average denier of the bundle of filaments spun through the spinneret 108 of the spin station 106 is constant or does not vary more than ⁇ 5%, according to some implementations.
  • the speed of the pump providing at least one of the molten polymer streams to the spin station may be increased while the speed of the pumps providing the other molten polymer streams to the spin station may be kept the same or decreased, resulting in the yam having more of the color of the stream being pumped at a higher speed than the other streams.
  • Increasing and decreasing the speed of at least one or more pumps can also be varied according to a certain frequency and amplitude, in some implementations, creating portions of a length of the bundle that have a different color(s), hue(s), and/or dyability characteristic(s) than other portions of the length.
  • the instructions also cause the processor 110 to adjust the timing of the volumetric flow rate changes and hence adjust the corresponding denier and/or color changes in the yarn. For example, the following description is for a sequence of steps performed by the processor 110.
  • the instructions cause the spin pump 104a to be at a higher speed (for example, 50% of maximum speed) and the spin pump 104b and 104c to be at a lower speed (for example, each at 25% of maximum speed) for an initial xl seconds (for example, xl is 1 sec, 2 secs, 3 secs, 4, secs, 5 secs, 6 secs, 7 secs, 8 secs, and so on).
  • xl is 1 sec, 2 secs, 3 secs, 4, secs, 5 secs, 6 secs, 7 secs, 8 secs, and so on.
  • the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a and 104b are at a lower speed (for example 25% of maximum speed) and the spin pump 104c is at a higher speed (for example 50% of maximum speed) for x2 seconds.
  • xl x2
  • xl x2
  • xl is different from x2.
  • the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a and 104c are at a lower speed (for example at 25% of maximum speed) and spin pump 104b is at a higher speed (for example at 50% of maximum speed) for x3 seconds.
  • x3 can be equal to xl and/or x2. In other embodiments, x3 can be different from xl and/or x2.
  • the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a, 104b, 104c are at the same speed (for example, each at 33.33% of the maximum speed). The above sequence or a variation thereof is repeated to produce the desired color variation in the yam.
  • the instructions cause the processor 110 to randomize the above steps to produce random color variation in the yarn.
  • an internal clock associated with the processor 110 selects an overall timer with a first random number greater than 0 and to and including y secs (for example, y can be 5 secs, 6 secs, 7 secs, 7.5 secs, 8 secs, 9 secs, 10 secs, and so on).
  • the instructions cause the processor 110 to change the speed of the pumps such that pumps 104a and 104b are at a random lower speed (for example, at 20% of maximum speed and 28% maximum speed respectively) and spin pump 104c is at a higher speed (for example, at 52% of maximum speed).
  • the instructions also cause the processor 110 to determine the volumetric flow rate of each polymer to be pumped by each spin pump 104a, 104b, 104c to achieve the desired ratio and generate the instructions to the spin pumps 104a, 104b, 104c based on the volumetric flow rate determinations.
  • the volumetric flow rate for each spin pump 104a, 104b, 104c may be determined by another processor or otherwise input into the system 100.
  • the instructions to the spin pumps 104a, 104b, 104c may be generated by another processor or otherwise input into the system 100.
  • the computer readable instructions are stored on a computer memory that is in electrical communication with the processor 110 and disposed near the processor (e.g., on the same circuit board and/or in the same housing). And, in other implementations, the computer readable instructions are stored on a computer memory that is in electrical communication with the processor but is remotely located from the processor. In some instances, the processor 110 and memory form a computer device such as that shown in FIG. 10, which is described below.
  • FIG. 10 illustrates an example computing system that includes a processor, which can include processor 110. The system in FIG. 10 may be used by system 100, for example.
  • the radial cross-sectional shape of each filament in any of the first through seventh aspects may be the same as the other filaments or different, e.g.
  • the manifold 105 in FIG. 1 is a static manifold, such as a honeycomb or static mixer.
  • the manifold may be a dynamic manifold having multiple inlets in fluid communication with valves for controlling the flow through each inlet and the outlets.
  • the valves are selectively opened or closed to regulate the flow of the polymer streams through the manifold.
  • the dynamic manifold comprises N inlets and at least N +1 outlets, wherein each inlet is in fluid communication with a respective one of N extruders, and at least one inlet is in communication with at least two outlets via channels that extend between the inlet and the outlets and comprises at least one valve that controls flow of the polymer stream between the at least one inlet and the at least two outlets.
  • FIGS. 4A-4D illustrates an example dynamic manifold 800 that may be used in the spin stations described herein and shown in FIGS. 1-3.
  • the dynamic manifold has inlets 810, 812, 813, and each inlet 810, 812, 813 is in fluid communication with each pump 801, 802, 803, which is in fluid communication with each extruder (not shown).
  • Inlet 810 is in fluid communication with outlet 820 through channel 815
  • inlet 812 is in fluid communication with outlet 822 through channel 816 and with outlet 824 through channel 817
  • inlet 813 is in fluid communication with outlet 826 through channel 818.
  • a mixing plate 865 is disposed between the dynamic manifold 800 and the spinnerets 850, 860.
  • the mixing plate 865 defines two channels 865a, 865b.
  • An inlet to channel 865a is adjacent outlets 820, 822, and an inlet to channel 865b is adjacent outlets 824, 826.
  • An outlet to channel 865a is adjacent to and feeds spinneret 860, and an outlet to channel 865b is adjacent to and feeds spinneret 850.
  • Valves 221, 222 are disposed within channels 816 and 817, respectively. Valves 221, 222 are selectively opened and closed to regulate the flow of the polymer stream from pump 802 to the outlets 822, 824. As shown in FIG. 4A, valve 221 is completely closed and valve 222 is completely open, which causes the polymer stream from pump 802 to be fully directed to outlet 824. Because outlet 824 is adjacent outlet 826 and these outlets 824, 826 ultimately feed spinneret 850, the bundle of filaments 870 spun from spinneret 850 include the polymer streams from pumps 802 and 803. And, because outlet 822 is not receiving any polymer from pump 802, the bundle of filaments 880 spun from spinneret 860 only includes the polymer stream from pump 801.
  • valve 222 is completely closed and valve 221 is completely open, which causes the polymer stream from pump 802 to be fully directed to outlet 822. Because outlet 822 is adjacent outlet 820 and these outlets 822, 820 feed spinneret 860, the bundle of filaments 880 spun from spinneret 860 include the polymer streams from pumps 801 and 802. And, because outlet 824 is not receiving any polymer from pump 802, the bundle of filaments 870 spun from spinneret 850 only includes the polymer stream from pump 803.
  • valves 221, 222 are completely open, which causes the polymer stream from pump 802 to be divided between outlets 822 and 824.
  • the bundle of filaments 880 spun from spinneret 860 includes the polymer streams from pumps 801 and 802, and the bundle of filaments 870 spun from spinneret 850 includes the polymer streams from pumps 802 and 803.
  • the amount of polymer stream from pump 802 that is spun through spinneret 860 is half of the amount that was spun through the spinneret 860 in FIG. 4B
  • the amount of polymer stream from pump 802 that is spun through spinneret 850 is half of the amount that was spun through the spinneret 850 in FIG. 4A.
  • FIG. 4A As shown in FIG.
  • valves 221, 222 are completely closed, which causes the polymer stream from pump 802 to not reach outlets 822, 824.
  • the yarn would not include the color, hue, luster, and/or dyability characteristic of the polymer stream from pump 802 while the valve 221, 222 are closed.
  • FIGS. 4A-4D show the valves 221, 222 completely open or closed, the valves 221, 222 can be partially open/closed to control the amount of polymer stream being fed to the spinnerets 850, 860.
  • other inlets in the dynamic manifold may have more than one channel between the inlet and multiple outlets and valves within the channels to control the volumetric flow rate of polymer flowing to each spinneret.
  • inlets that are in communication with more than one channel may include one valve within the inlet that controls the flow of the polymer stream to the channels that are in fluid communication with the respective inlet.
  • the system 100 may be run at a speed of at least 2600 meters per minute, which is faster than prior art systems, since the denier per filament is not changed during a color change.
  • the speed may be increased or decreased based on the desired appearance. And depending on the operating parameters of the system, a change in speed may not affect the appearance of the yarn.
  • Filaments produced using the system 100 have better wear properties because the color, luster, and/or dye extends through the full mass of the filament. Having the color, luster, and/or dye extend through the entire filament also improves the appearance of cut pile in carpets.
  • the system 100 is faster and less expensive than prior art systems because the average denier per filament and/or the average denier per bundle can be kept substantially constant and the pumps 104a-104c do not have to stop to allow for changes in the color of the yarn produced. This system 100 also produces less waste by avoiding the need to stop and start at each color change.
  • Various implementations also include a yarn that includes a plurality of filaments.
  • the plurality of filaments has at least a first set of filaments and a second set of filaments, wherein the first set of filaments has a first color, hue, luster, and/or dyability characteristic at a radial cross section of the plurality of filaments and the second set of filaments has a second color, hue, luster, and/or dyability characteristic at the radial cross section, and the first color, hue, luster, and/or dyability characteristic is different than the second color, hue, luster, and/or dyability characteristic.
  • the yarn is bulked continuous filament (BCF) yam.
  • the yarn is made according to any of the processes described above and/or by any of the systems described above.
  • some implementations include a carpet that includes pile made with this yam.
  • Various implementations also include a yarn that includes a plurality of filaments that have at least a first set of filaments and a second set of filaments.
  • the first set of filaments has a first color, hue, luster, and/or dyability characteristic at a radial cross section of the plurality of filaments
  • the second set of filaments has a second color, hue, luster, and/or dyability characteristic at the radial cross section
  • the first color, hue, luster, and/or dyability characteristic is different than the second color, hue, luster, and/or dyability characteristic.
  • the yam is bulked continuous filament (BCF) yam.
  • the yarn may be made according to any of the processes described above and/or by any of the systems described above.
  • some implementations include a carpet that includes pile made with this yam.
  • carpet having changing colors such as the carpet described above, can be made from one continuous BCF yam, instead of having to stop the process to switch out yam having a different color.
  • the yarn may be a bulked continuous filament (BCF) yarn that may be (1) extruded and drawn in a continuous operation, (2) extruded, drawn, and textured in a continuous operation, (3) extruded and taken up in one step and is then later unwound, drawn, and textured in another step, or (4) extruded, drawn, and textured in one or more operations.
  • BCF bulked continuous filament
  • the BCF yarn could be used as yarn in carpet or in apparel, for example.
  • the system shown in FIG. 1 has three extruders and three pumps and one spinning station for producing one bundle of filaments, this system can be scaled in other implementations to produce M yams, wherein M is an integer greater than one.
  • the system allows for the color, hue, luster, and/or dyability characteristic of the filaments in each yarn to be altered by changing volumetric flow rates of spin pumps in fluid communication and paired with each extruder, without changing the dye sourcing or having to add additional extruders to the system.
  • the system includes N extruders, wherein N is an integer greater than one, M spin stations, and a processor.
  • the N extruders each comprise a polymer having a color, hue, luster, and/or dyability characteristic different from each other.
  • the M spin stations each produce one yam and receive molten polymer streams from the N extruders.
  • Each of the M spin stations includes at least one spinneret through which a plurality of melt-spun filaments are spun from at least two of the molten polymer streams received by the respective spin station and N spin pumps upstream of the spinneret for the respective spin station, wherein each spin pump is in fluid communication and is paired with one of the N extruders.
  • the processor is in electrical communication with the N*M spin pumps and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in each of the M yams spun from each of the M spin stations.
  • At least two ratios of the M ratios are different. In other implementations, all of the M ratios are different.
  • the system 200 in FIG. 2 includes three extruders 202a-202c and two spin stations 206a, 206b.
  • Each spin station 206a, 206b has a spinneret 208a, 208b, respectively, and a group of spin pumps 204al-204cl and 204a2-204c2, respectively.
  • Spin pumps 204al and 204a2 are paired with extruder 202a.
  • Spin pumps 204b 1 and 204b2 are paired with extruder 202b.
  • spin pumps 204c 1 and 204c2 are paired with extruder 202c.
  • the first spin station 206a includes a first group of spin pumps 204al-204cl
  • the second spin station 206b includes a second group of spin pumps 204a2-204c2.
  • Each spin pump 204al-204cl in the first group of spin pumps is in fluid communication with and is paired with one of the extruders 202a-202c and is in fluid communication with the first manifold 205a, the first mixing plate 207a, and the first spinneret 208a.
  • each spin pump 204a2-204c2 in the second group of spin pumps is in fluid communication with and is paired with one of the extruders 202a-202c and is in fluid communication with the second manifold 205b, the second mixing plate 207b, and the second spinneret 208b. Accordingly, polymer pumped from the extruders 202a-202c by the first group of spin pumps 204al-204cl is spun through the first spinneret 208a, and polymer pumped from the extruders 202a-202c by the second group of spin pumps 204a2-204c2 is spun through the second spinneret 208b.
  • the denier per filament of the filaments spun through each spinneret 208a, 208b relative to other filaments spun from the same spinneret 208a, 208b may be the same or different. And, the denier per filament of the filaments spun through each spinneret 208a, 208b relative to the filaments spun from the other spinneret 208a, 208b may be the same or different.
  • the total volumetric flow rate extruded from each extruder 202a-202c is the sum of the volumetric flow rates pumped by the spin pumps 204al-204c2 that are paired with the respective extruder 202a-202c.
  • the total volumetric flow rate extruded from extruder 202a is the sum of the volumetric flow rates pumped by spin pumps 204al and 204a2.
  • the total volumetric flow rate extruded from the extruder 202b is the sum of the volumetric flow rates pumped by spin pumps 204b 1 and 204b2.
  • the processor 210 is configured to execute computer readable instructions that cause the processor 210 to (1) adjust the volumetric flow rate of the polymers pumped from each spin pump 204al-204cl of the first group of spin pumps to achieve a first ratio of polymers to be included in the first bundle of filaments 214a spun from the first spinneret 208a of the first spin station 206a and (2) adjust the volumetric flow rate of the polymers pumped from each spin pump 204a2-204c2 of the second group of spin pumps to achieve a second ratio of the polymers to be included in the second bundle filaments 214b spun from the second spinneret 208b of the second spin station 206b.
  • the processor 210 and memory form a computer device such as that shown in FIG. 10, which is described below.
  • FIG. 10 illustrates an example computing system that includes a processor, which can include processor 210. The system in FIG. 10 may be used by system 200, for example.
  • the ratio to be included in each of the bundles of filaments 214a, 214b are different.
  • the colors, hues, lusters, and/or dyability characteristics of the bundle of filaments 214a, 214b may include filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the first extruder 202a, filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the second extruder 202b, filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the third extruder 202c, and/or filaments having a color, hue, luster, and/or dyability characteristic that is a mixture of the colors, hues, lusters, and/or dyability characteristics from the extruders 202a-202c.
  • the average denier of the bundle of filaments spun through each spinneret 208a, 208b is constant or does not vary more than ⁇ 5%. However, the average denier per filament of the filaments spun through the first spinneret 208a of the first spin station 206a may be different from the average denier per filament of the filaments spun through the second spinneret 208b of the second spin stations 206b.
  • the polymer streams from at least two of the extruders are spun together but separately from the polymer stream from at least one other extruder.
  • FIG. 3A illustrates an implementation that is similar to FIG.
  • the spin station 306 includes two spinnerets 308a, 308b, two mixing plates 307a, 307b, and two manifolds 305a, 305b.
  • the mixing plates can be one piece and/or the manifolds can be one piece.
  • Polymer streams from extruders 302a and 302b are pumped into manifold 305a by pumps 304a, 304b, respectively, and are spun into filaments 314a through spinneret 308a.
  • the colors, hues, lusters, and/or dyability characteristics of the bundle of filaments 314a may include filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the first extruder 302a, filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the second extruder 302b, and/or filaments having a color, hue, luster, and/or dyability characteristic that is a mixture of the colors, hues, lusters, and/or dyability characteristics from the extruders 202a-202b.
  • the bundle of filaments 314a has a blended appearance based on the streams spun through spinneret 308a.
  • the colors, hues, lusters, and/or dyability characteristics of the bundle of filaments 314b has filaments having the color, hue, luster, and/or dyability characteristic of the polymer in the third extruder 302c.
  • the variation in the volumetric flow rate of the polymer displaced by the extruder may be based on, but is not limited to, the type of polymer, a size and/or shape of the capillaries of the spinneret, the temperature of the polymer, and the denier per filament of the filaments spun from that spinneret.
  • the volumetric flow rate is greater than zero and can be varied such that the flow of the polymer stream through the spinneret is continuous and supports continuous filament formation.
  • the average denier of the yarn that is made with the bundles 314a, 314b can be kept substantially constant (e.g., ⁇ 5% variation) if the sum of volumetric flow rate of the pumps 304a and 304b remains substantially constant and if the volumetric flow rate of pump 304c remains substantially constant.
  • changing the sum of the volumetric flow rate of pumps 304a and 304b or changing the volumetric flow rate displaced by pump 304c may change the average denier of the yam.
  • the bundles 314a, 314b produced by system 300 in FIG. 3 A can be drawn separately by drawing device 360, which is a plurality of godets, after the spinning process, assuming that the filaments in bundle 314b are not subject to breakage due to their denier per filament, radial cross-sectional shape, or otherwise.
  • the drawing device 360 is at least one or more godets, for example, but in other implementations, it can also include a draw point localizer.
  • FIG. 3B illustrates a schematic diagram of optional post-spinning processes for the spinning system in FIG. 3A. These optional post-spinning processes enhance the color contributed to the yarn by each bundle of filaments 314a, 314b. Each process can be used when there are two or more spun filament bundles that have different colors, hues, lusters, and/or dyability characteristics.
  • the processes include (1) tacking spun filaments in at least one bundle separately from the other bundles after spinning and prior to or during the drawing process, (2) texturing tacked spun filaments in at least one bundle separately from the other bundles after the drawing process, and (3) tacking textured and tacked spun filaments in at least one bundle separately from the other bundles and feeding the bundles to a mixing cam that feeds the bundles to a final tacking device for tacking together the bundles into a yam.
  • each bundle of spun filaments 314a, and 314b are tacked individually by a tacking device 315, 325, respectively.
  • each bundle 314a, 314b is physically separated from the other bundle and only filaments belonging to the respective bundle are tacked together.
  • the tacking devices 315, 325 are air entanglers. The tacking is done with air entangling every 6 to 155 mm (e.g., 20 to 50 mm).
  • the tacking devices 315, 325 may use 2 to 6 bar pressure, but the pressure may increase with an increased number of filaments, increased denier per filament, and/or increased speed of filament production.
  • the tacking devices 315, 325 are air entanglers that use room temperature air for entangling the filaments.
  • the tacking devices include heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example.
  • air entanglement can be applied to one or more of the bundles by turning off or on air to 315, 325.
  • air can be applied constantly or in an on/off sequence to get the desired end effect.
  • the bundles of spun filaments are first elongated partially before being tacked individually. After the tacking step, the spun, tacked bundles are further elongated to the final denier.
  • each bundle of tacked and drawn filaments 317, 327 are texturized separately through texturizers 371, 372, respectively.
  • bundles 318, 328 of texturized filaments are provided.
  • the texturizers 371, 372 may apply air, steam, heat, mechanical force, or a combination of one of more of the above to the filaments to cause the filaments to bulk (or crimp/shrink).
  • the bundles 317, 327 are texturized to have a bulk (or crimp or shrinkage) of 5-20%.
  • Texturizing individual bundles of filaments separately when using bundles with different colors, hues, lusters, and/or dyability characteristics, provides a more pronounced color, hue, luster, and/or dyability characteristic along the axial length of the BCF yarn.
  • the filaments that are texturized separately tend to stay more grouped together during the rest of the production steps to make the BCF yarn, which results in the color, hue, luster, and/or dyability characteristic of this bundle of spun filaments being more pronounced along the length of the BCF yam.
  • the texturized filaments 318, 328 are provided to an individual color entanglement process prior to the final tacking at tacking device 380.
  • the bundles 318, 328 of texturized filaments are fed into separate tacking devices 319, 329 to tack individually each bundle of texturized spun filaments.
  • Tacking devices 319, 329 are air entanglers that use room temperature air applied at 2 bar to 6 bar pressure, for example, for entangling the filaments every 15 to 155 mm. But the pressure may increase with an increased number of filaments, increased denier per filament, and/or increased speed of filament production.
  • the tacking devices 319, 329 include heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example. The tacking may be done more frequently for a specific look desired. For example, with more frequent tacking, the yarn looks less bulky and the color separation is reduced, which results in a more blended look for the colors.
  • the mixing cam 400 positions bundles tacked by tacking devices 319, 329 relative to each other prior to being tacked together in final tacking device 380.
  • the mixing cam 400 is cylindrical and has an external surface defining a plurality of grooves for receiving and guiding the texturized and tacked bundles.
  • the mixing cam 400 is rotatable about its central axis or can be held stationary. If rotated, the mixing cam 400 varies which side of the bundles are presented to the tacking jet in the tacking device 380, which affects how the bundles (and filaments therein) are layered relative to each other. In some embodiments, the positions are randomly varied.
  • the speed of rotation can be changed to provide a different appearance in the yarn 391.
  • one or more of the bundles 320, 321 may have a first color on one side of the bundle 320, 321 and a second color on another side of the bundle 320, 321, wherein the sides of the bundle are circumferentially spaced apart but intersected by the same radial plane. It may be desired to have the first color on an exterior facing surface of an arc in a carpet loop in one area of the carpet and the second color on an exterior facing surface of an arc in a carpet loop in another area of the carpet.
  • Rotating the cam 400 may “flip” one or more of the bundles 320, 321 about its axis such that the desired color is oriented on a portion of the outer surface of the yarn 391 such that the desired color is on the exterior facing surface of the arc in the carpet loop. The undesired color for that portion of the carpet is hidden on the inside facing surface of the loop. Rotation of the cam 400 ensures that the filaments that run on the outside of the loop are changing due to a specific mechanical means and not necessarily natural occurrences in downstream processes.
  • the positions of the bundles 320, 321 are directed by the mixing cam 400 to the final tacking device 380 but their relative positions are not varied.
  • the bundles 320, 321 are fed to the tacking device 380 directly or they are fed via a stationary guide disposed between the intermediate tacking devices 319, 329 and the tacking device 380.
  • the tacked texturized bundles 320, 321 positioned by mixing cam 400 are thereafter tacked together by tacking device 380 into a BCF yarn 391. This tacking is done with air entangling every 12 to 80 mm.
  • Tacking device 380 is an air entangler that uses room temperature air applied at 2 bar to 6 bar pressure, for example, for entangling the filaments. But the pressure may increase with an increased number of filaments, increased denier per filament, and/or increased speed of filament production.
  • the tacking device 380 includes heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example.
  • the bundles 320, 321 are tacked and as such provide a BCF yarn 391 comprising an average of 24-360 filaments of 2 to 40 DPF each.
  • the tacking may be done more frequently for a specific look desired. For example, with more frequent tacking, the yarn looks less bulky and the color separation is reduced, which results in a more blended look for the colors.
  • the effect of this individual tacking and guidance via a mixing cam cause the colors and/or hues in the yarn to be more structured and positioned.
  • the positioning of the colored bundles in the yam cause bundles to be more pronounced in the final carpet surface.
  • the positioning of the color, hue, luster, and/or dyability characteristic in the BCF yarn has as effect that this color, hue, luster, and/or dyability characteristic can be locally more present on the top side of the tuft oriented upwards, away from the backing of the carpet, or hidden at the low side of the tuft oriented towards the backing of the carpet.
  • the effect is the provision of very vivid and pronounced color zones on the carpet.
  • each mixing plate 107, 207a, 207b, 307a, 307b defines a single channel that receives all of the molten polymer streams that flow through the respective manifold 105, 205a, 205b, 305a, 305b that is upstream of the mixing plate 107, 207a, 207b, 307a, 307b.
  • the mixing plates 107, 207a, 207b, 307a, 307b are not separating the molten polymer streams before the streams flow through the spinnerets 108, 208a, 208b, 308a, 308b.
  • the mixing plate may include a plurality of channels for separating or mixing a plurality of molten polymer streams.
  • FIGS. 4A-4D illustrate a mixing plate 865 having two channels 865a, 865b defined by the plate 865 that receives molten polymer streams from the manifold 800 upstream from the mixing plate 865. Each channel 865a, 865b feeds separate spinnerets. Thus, if two or more molten polymer streams are received into one of the channels 865a, 865b, the two or more streams are at least partially mixed in the respective channel 865a, 865b.
  • FIGS. 4A-4D FIG.
  • FIG. 5 illustrates a system 500 that includes a mixing plate 507 defining two channels 507a, 507b therethrough.
  • the mixing plate 507 is disposed between a static manifold 505 and spinneret 508.
  • the molten polymer stream from extruder 502a is pumped by pump 504a into the manifold 505, which feeds the stream into channel 507a of the mixing plate, which feeds the stream through spinneret 508.
  • the molten polymer streams from extruders 502b, 502c are pumped by pumps 504b, 504c, respectively, into the manifold 505, which feeds the streams into channel 507b of the mixing plate, which feeds the streams through spinneret 508.
  • the stream from extruder 502a is not mixed or spun together with the streams from extruders 502b, 502c in the manifold 505 or the mixing plate 507, but the streams from extruders 502b, 502c are at least partially mixed in the channel 507b prior to being spun through the spinneret 508.
  • the DPF of the filaments in each of the bundles are equal. However, in other embodiments, at least some of the filaments in one bundle may have a different DPF than the other filaments in the bundle. Or, in some embodiments, the filaments in one bundle may have the same DPF as other filaments in the bundle but the DPF of those filaments may be different from the DPF of the filaments in another bundle. And, in some embodiments, the number of filaments in the bundles are equal. And, in other embodiments, the number of filaments in each bundle may differ.
  • FIG. 6 illustrates the results of a color sequencing test using the system 100 shown in FIG. 1.
  • extruder 102a had magenta molten Nylon
  • extruder 102b had cyan molten Nylon
  • extruder 102c had yellow molten Nylon.
  • the pumps 104a, 104b, 104c were operated at the same or different RPMs to change the color of the filaments 114.
  • the filament colors changed in response to the RPM changes in less than 10 seconds. For example, when pump 104a was operated at full capacity (e.g., 30 RPM) and pumps 104b and 104c were stopped (0 RPM), the filaments 114 were magenta, as shown in Al.
  • FIG. 7B illustrates rolls of yam produced using the system of FIG. 1.
  • the color of the yam varies over the length of the yarn, due to the color sequencing changes described above in in relation to FIG. 6 and shown in C1-C6.
  • the color is more blended than the yam shown in FIG. 7A.
  • the yam in FIG. 7A is made using the same polymers having the same colors as are used in the yarn of FIG. 7B and by adjusting the pump output to adjust the color of the yarn, but the molten Nylon streams from each extruder are spun separately from each other through separate spinnerets.
  • FIG. 8 illustrates carpets 1000, 1002 that have pile made with the BCF yarns shown in FIGS. 7B and 7A, respectively.
  • FIG. 9 illustrates a comparison of rolls of BCF yam made according to the system described above in relation to FIG. 7A (marked Al, Bl, Cl) with those made with the system of FIG. 1 (marked A2, B2, C2) and according to different pump speed ratios.
  • the pump ratio is 10:4: 1 (e.g., the speeds for the pumps for each extruder are varied to be 20:8:2 RPM).
  • the pump ratio is 6:3 : 1 (e.g., the speeds for the pumps for each extruder are varied to be 18:9:3 RPM).
  • C1-C2 the pump ratio is 4: 1 : 1 (e.g., the speeds for the pumps for each extruder are 20:5:5 RPM).
  • a color or hue difference as expressed with a Delta E value of 1.0 is preferred. Even better the difference or variation at least encompasses a color or hue difference as expressed by Delta E of at least 5.0 or at least 10.0. Delta E is a measure of change in visual perception of two given colors.
  • FIG. 10 illustrates an example computing device that can be used for controlling the pumps of the system 100.
  • “computing device” or “computer” may include a plurality of computers.
  • the computers may include one or more hardware components such as, for example, a processor 1021, a random access memory (RAM) module 1022, a read-only memory (ROM) module 1023, a storage 1024, a database 1025, one or more input/output (I/O) devices 1026, and an interface 1027. All of the hardware components listed above may not be necessary to practice the methods described herein.
  • the computer may include one or more software components such as, for example, a computer-readable medium including computer executable instructions for performing a method associated with the example embodiments. It is contemplated that one or more of the hardware components listed above may be implemented using software.
  • storage 1024 may include a software partition associated with one or more other hardware components. It is understood that the components listed above are examples only and not intended to be limiting.
  • Processor 1021 may include one or more processors, each configured to execute instructions and process data to perform one or more functions associated with a computer for producing at least one bundle of filaments and/or at least one yam.
  • Processor 1021 may be communicatively coupled to RAM 1022, ROM 1023, storage 1024, database 1025, I/O devices 1026, and interface 1027.
  • Processor 1021 may be configured to execute sequences of computer program instructions to perform various processes. The computer program instructions may be loaded into RAM 1022 for execution by processor 1021.
  • RAM 1022 and ROM 1023 may each include one or more devices for storing information associated with operation of processor 1021.
  • ROM 1023 may include a memory device configured to access and store information associated with the computer, including information for identifying, initializing, and monitoring the operation of one or more components and subsystems.
  • RAM 1022 may include a memory device for storing data associated with one or more operations of processor 1021.
  • ROM 1023 may load instructions into RAM 1022 for execution by processor 1021.
  • Storage 1024 may include any type of mass storage device configured to store information that processor 1021 may need to perform processes consistent with the disclosed embodiments.
  • storage 1024 may include one or more magnetic and/or optical disk devices, such as hard drives, CD-ROMs, DVD-ROMs, or any other type of mass media device.
  • Database 1025 may include one or more software and/or hardware components that cooperate to store, organize, sort, filter, and/or arrange data used by the computer and/or processor 1021.
  • database 1025 may store computer readable instructions that cause the processor 1021 to adjust the volumetric flow rate of the polymers pumped by each spin pump to achieve a ratio of the polymers to be included in the filaments spun from the at least one spinneret. It is contemplated that database 1025 may store additional and/or different information than that listed above.
  • I/O devices 1026 may include one or more components configured to communicate information with a user associated with computer.
  • I/O devices may include a console with an integrated keyboard and mouse to allow a user to maintain a database of digital images, results of the analysis of the digital images, metrics, and the like.
  • I/O devices 1026 may also include a display including a graphical user interface (GUI) for outputting information on a monitor.
  • GUI graphical user interface
  • I/O devices 1026 may also include peripheral devices such as, for example, a printer for printing information associated with the computer, a user-accessible disk drive (e.g., a USB port, a floppy, CD-ROM, or DVD- ROM drive, etc.) to allow a user to input data stored on a portable media device, a microphone, a speaker system, or any other suitable type of interface device.
  • peripheral devices such as, for example, a printer for printing information associated with the computer, a user-accessible disk drive (e.g., a USB port, a floppy, CD-ROM, or DVD- ROM drive, etc.) to allow a user to input data stored on a portable media device, a microphone, a speaker system, or any other suitable type of interface device.
  • Interface 1027 may include one or more components configured to transmit and receive data via a communication network, such as the Internet, a local area network, a workstation peer-to-peer network, a direct link network, a wireless network, or any other suitable communication platform.
  • interface 1027 may include one or more modulators, demodulators, multiplexers, demultiplexers, network communication devices, wireless devices, antennas, modems, and any other type of device configured to enable data communication via a communication network.
  • These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutations of these components may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a device is disclosed and discussed every combination and permutation of the device, and the modifications that are possible are specifically contemplated unless specifically indicated to the contrary. Likewise, any subset or combination of these is also specifically contemplated and disclosed.

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Abstract

L'invention concerne des systèmes de production de M fils, M ≥ 1, comprenant N extrudeuses, M postes de filage, et un processeur, où N = 1. Chaque extrudeuse comprend un polymère ayant une caractéristique de couleur, de teinte, de lustre et/ou de teinture, qui sont différentes les unes des autres. Chaque poste de filage produit un fil comprenant au moins un faisceau de filaments. Chaque poste de filage comprend au moins une filière à travers laquelle des filaments sont filés à partir d'au moins deux flux de polymère thermoplastique fondu reçus par le poste de filage respectif et N pompes de filage en amont de la filière du poste de filage respectif. Chaque pompe de filage est jumelée à l'une des N extrudeuses. Le processeur est en communication électrique avec les N*M pompes de filage et est configuré pour régler le débit volumétrique des polymères pompés à partir de chaque pompe de filage pour obtenir un rapport des polymères à inclure dans chacun des M fils.
PCT/IB2022/061694 2021-12-15 2022-12-02 Systèmes et procédés de production d'un faisceau de filaments et/ou d'un fil WO2023111758A1 (fr)

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Title
ANONYMOUS: "Acid dye", 1 January 2000 (2000-01-01), pages 1 - 5, XP093076022, Retrieved from the Internet <URL:https://en.wikipedia.org/wiki/Acid_dye> [retrieved on 20230824] *
ANONYMOUS: "Disperse dye", 2000, pages 1 - 1, XP093076629, Retrieved from the Internet <URL:https://en.wikipedia.org/wiki/Disperse_dye> [retrieved on 20230124] *

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