WO2023116211A1 - 一种黑色仿棉纤维的制备方法 - Google Patents

一种黑色仿棉纤维的制备方法 Download PDF

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WO2023116211A1
WO2023116211A1 PCT/CN2022/129160 CN2022129160W WO2023116211A1 WO 2023116211 A1 WO2023116211 A1 WO 2023116211A1 CN 2022129160 W CN2022129160 W CN 2022129160W WO 2023116211 A1 WO2023116211 A1 WO 2023116211A1
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Prior art keywords
black
tow
tensioner
guide
wire
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PCT/CN2022/129160
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English (en)
French (fr)
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范红卫
沈建根
王丽丽
刘成柱
汤方明
袁正平
杨超明
孙晓华
寇婉婷
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江苏恒力化纤股份有限公司
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Publication of WO2023116211A1 publication Critical patent/WO2023116211A1/zh

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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
    • 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
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/04—Pigments
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0206—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/028—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by twisting or false-twisting at least two filaments, yarns or threads, fixing the twist and separating the filaments, yarns or threads
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0286—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist characterised by the use of certain filaments, fibres or 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
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear

Definitions

  • the invention belongs to the technical field of polyester fibers and relates to a method for preparing black cotton-like fibers.
  • Polyester is polyethylene terephthalate (PET) produced by polycondensation of terephthalic acid (PTA) and ethylene glycol (EG). Polyester is the largest category of synthetic fibers, and its output ranks first among all chemical fibers. At present, the main varieties in the market are pre-oriented yarn POY, fully drawn yarn FDY, stretched textured yarn DTY, etc.
  • Polyester pre-oriented yarn also known as polyester partially oriented yarn
  • high-speed spinning spin spinning speed 3000-3600m/min.
  • UDY undrawn yarn
  • the as-spun yarn obtained by the high-speed spinning process has a certain degree of orientation, and can be directly stretched and deformed to obtain a textured yarn, thereby shortening the process flow.
  • Fully drawn yarn FDY is a drawn yarn with a fully oriented structure produced by introducing drawing into POY high-speed spinning, and integrating spinning, drawing and winding into one continuous process. Compared with POY, FDY has a common high orientation, but the crystallinity of FDY is higher than that of POY. Although POY and FDY have a certain degree of orientation, their properties are still unstable compared with finished silk, and they do not have wearability, so they must be post-processed. More than 90% of the post-processing is stretched and deformed to produce stretched textured yarn DTY (commonly known as low elastic yarn).
  • Polyester low elastic yarn is a new type of yarn with high crimp and bulkiness obtained by deforming and heat setting by using polyester filament as raw material and utilizing the thermoplasticity of the fiber.
  • DTY filament products are soft and bulky. Fabrics made of DTY have good bulkiness and warmth retention. They can generally be used in clothing, tents, bags, etc.
  • carbon black is usually used as the masterbatch to color polyester filaments, but inorganic additives such as carbon black will cause the raw material tow to be rough, and will wear out the existing first yarn guide in a short time.
  • the service life of the yarn guide is reduced, and the wear between the tow and the yarn guide can also negatively affect the performance of the tow.
  • the surface of the groove is relatively rough, which will generate a large resistance pulling force on the tow, so that the tow will generate a high friction between the first yarn guide and the first wire feeding roller.
  • Tension the tension will be transmitted to the first feed roller and the second feed roller to pull the tow, resulting in excessive tension of the tow, making it impossible for the network nozzle to secure the tow network, resulting in off-network and product quality problems. making the product unmanufacturable. Therefore, it is necessary to optimize the production process to solve the problems of high wear of the yarn guide and high tension of the tow, so as to make the pre-network more stable.
  • the purpose of the present invention is to solve the above-mentioned problems that exist in the prior art, and a kind of preparation method of black imitation cotton fiber is provided.
  • a preparation method of black imitation cotton fiber adopting DTY texturizing process, polyester POY and polyester FDY fiber sequentially pass through the first yarn guide, guide roller, tensioner, first yarn feeding roller, pre-network, and second yarn feeding Roller, first deformation heating box, cooling plate, false twister, third feeding roller, middle network device, shaping heating box, shaping feeding roller, oiling, winding and forming to obtain black imitation cotton fiber;
  • polyester POY and polyester FDY fibers contain carbon black
  • the first wire guide is a wire guide wheel
  • the tensioner is a magnetic tensioner, which is a tension control device that generates damping through magnetic field conversion torque changes and has no mechanical friction.
  • the magnetic tensioner is small in size and easy to install;
  • the bottom of the groove of the godet wheel is in contact;
  • the set tension of the tensioner is 7-10cN (adjusted by the sensor in the tensioner, and the direction of tension points to both ends of the wire harness), and the first wire guider is replaced by a godet roller
  • the godet wheel although the tension of the tow is greatly reduced, it will cause the tension of the tow to be difficult to control, the tension is unstable, and the jitter of the tow is serious.
  • After applying a tension of 7 to 10cN the jitter of the tow can be greatly reduced;
  • the linear speed ratio of the first wire feeding roller to the second wire feeding roller is 1.03-1.04, which forms a certain overfeeding ratio and facilitates the formation of the pre-network.
  • the godet wheel rim width of described first wire guide is 20 ⁇ 25mm
  • the outer diameter of the godet wheel is 9.4 ⁇ 10.7mm
  • the groove bottom inner diameter is 6mm. ⁇ 7.4mm.
  • the tension of the tow is 2.5 to 5.0 cN during pre-networking, and the tension of the tow is still within this range after one year of continuous DTY texturing.
  • the carbon black content in the polyester POY and polyester FDY fibers is both 1.2 to 1.5 wt%.
  • the average particle size of carbon black is 0.3-0.4 ⁇ m.
  • the temperature of the box is 150-160°C
  • the linear speed ratio (stretch ratio) of the third wire feed roller to the second wire feed roller is 1.1-1.14
  • the setting overfeed rate is 4.0-5.0%
  • the winding speed is 500-600m /min, winding overfeed rate 2.0 ⁇ 3.0%.
  • the breaking strength of described black imitation cotton fiber is 2.1 ⁇ 2.3cN/dtex (test standard: GB/T 14344), and network degree is 90 ⁇ 100/meter ( Test standard: FZ/T 50001-2005), CV value of breaking strength ⁇ 6.00%;
  • the rate of change of the breaking strength, network degree and CV value of breaking strength of the black cotton-like fiber produced continuously for 60 days is not higher than 10%; , after producing the black cotton-like fiber for two consecutive months, the breaking strength and network degree of the obtained black cotton-like fiber decrease by no more than 10%, and the CV value of the breaking strength increases by no more than 10%.
  • Principle of the present invention is as follows:
  • Coloring polyester filaments with carbon black as the masterbatch will make the surface of the tow not smooth. Because the yarn guide cannot rotate around the axis in the existing texturing process, there is sliding friction between the tow and the yarn guide, resulting in When performing DTY texturing on polyester filaments, the first yarn guide will be worn out within 3 to 5 days. Since the first yarn guide is worn out for a short period of time, a groove will be formed, and the resistance tension generated when the tow passes through the groove Larger, the tension of the tow becomes larger when it passes through the first yarn guide, which can be as large as 20-25cN.
  • the tension of 20-25cN at the first yarn guide will increase the tension of the tow to 6-8cN during pre-network (if the holding is sufficient, the tension of the tow It will only be affected by the overfeed ratio, and once the grip is insufficient, the tow tension before the first silk feed roller will have an impact on the tow tension after the first silk feed roller.
  • the tow tension after the first silk feeding roller will increase), and if the tow tension is too large, the network nozzle of the pre-network will not be able to secure the tow network, resulting in off-network, which will make the tow
  • the double-filament cohesion is poor, resulting in many interruptions in the weaving process, and there are knots on the fabric surface, resulting in uneven fabric surface, serious affect product performance.
  • the present invention replaces the original first wire guide with a wire guide wheel, which can change the friction between the tow and the wire guide from sliding friction to rolling friction, which not only reduces the wear of the wire guide, but also greatly Reduce the tension of the tow as it passes through the first yarn guide.
  • the tension of the tow is greatly reduced, but after replacing it with a godet wheel, the tension of the tow is not easy to control, the tension is unstable, and the tension cannot be controlled in a stable range, and The godet wheel will cause the tension of the tow to be too small, and the tow will vibrate severely, resulting in floating yarn, making the production impossible.
  • the present invention applies a certain tension to the tow through the magnetic tensioner and the wire guide roller, the magnetic tensioner and the wire guide roller are placed between the first wire guide and the first wire feeding roller, and the distance between the magnetic tensioner and the first wire feeder is The feeding roller is closer, and the angle of the tow before and after contacting the groove bottom of the wire guide wheel with the magnetic tensioner is within a certain range, and the tow will exert pressure on the wire guide wheel during the movement, so that the angle becomes larger Therefore, the damping produced by the magnetic tensioner will form a reaction force with the pressure generated by the tow to keep the angle stable; the reaction force will form the tension of the tow for the tow.
  • the godet roller can stabilize the chattering phenomenon caused by the reduction of tension, which is of great help to control the tension through the tensioner.
  • the present invention can greatly reduce the vibration of the tow and keep it stable. Too high or too small tension is not conducive to the stability of the pre-network.
  • the present invention also forms overfeeding by setting the first silk feeding roller and the second silk feeding roller line speed ratio (overfeed ratio) to be 1.03 ⁇ 1.04, so that the tension of the tow in the pre-network stage is at 2.5 ⁇ 5.0cN (although Insufficient gripping of the first wire feed roller will cause the tension of the tow before the first wire feed roller to affect the tension of the tow after the first wire feed roller, but since the yarn guide is replaced by the wire guide wheel , and the tension of the wire bundle is controlled by a magnetic tensioner, which greatly reduces the tension of the wire bundle before the first wire feeding roller, which also greatly reduces the process difficulty of controlling the tension by controlling the overfeed ratio, and can fully realize the yarn
  • the tension of the beam in the pre-network stage is kept within the range of 2.5 ⁇ 5.0cN), which can stably make the net without causing loose nets and no floating threads.
  • the preparation method of a kind of black imitation cotton fiber of the present invention can improve tow network degree, and do not have scattered net, and this can make the cloth surface of the polyester low-stretch silk fabric containing carbon black that makes follow-up smooth, not easy to break ;
  • the preparation method of a kind of black imitation cotton fiber of the present invention can reduce the wearing and tearing of the first yarn guide, avoid resource loss.
  • Fig. 1 is a preparation process flow chart of the present invention
  • Fig. 2 is the sectional structure schematic diagram of godet wheel of the present invention.
  • 1-polyester POY and polyester FDY fiber 2-the first yarn guide, 3-the guide roller, 4-tensioner, 5-the first feeding roller, 6-pre-network, 7-the second feeding roller , 8-the first deformation heating box, 9-cooling plate, 10-false twister, 11-the third feeding roller, 12-internet device, 13-setting heating box, 14-setting feeding roller, 15-top Oil.
  • the CV value of the breaking strength of the black imitation cotton fiber that the first day makes in the embodiment of the present invention degree of network and breaking strength refers to the average value of the performance of the black imitation cotton fiber that produces all day in the first day; Continuous production 60
  • the breaking strength, network degree and CV value of the breaking strength of the black cotton-like fiber obtained after Tianhou refer to the average value of the properties of the black cotton-like fiber produced all day long on the 60th day.
  • the process of preparing black cotton-like fibers by using the DTY texturing process is as follows: as shown in Figure 1, polyester POY and polyester FDY fibers 1 containing carbon black with an average particle size of 0.3 to 0.4 ⁇ m pass through the first yarn guide 2, the first yarn guide, and the polyester FDY fiber 1 successively.
  • the first wire guide is guide wire
  • the wire guide wheel is in contact with the groove bottom of the first wire guide during the movement of the tow, and drives the first wire guide to rotate;
  • the material of the wire guide wheel is ceramic, the surface hardness of the groove bottom is 1500HV, and the friction coefficient between the groove bottom and the tow is is 0.2; as shown in Figure 2, the rim width of the godet wheel is 20mm, the outer diameter of the outer wheel is 9.4mm, and the inner diameter of the groove bottom is 6mm;
  • the tensioner is a magnetic tensioner;
  • the bottom of the groove of the wire wheel is in contact; the tension of the tensioner is set to 10cN;
  • the process parameters are: pre-screen nozzle air pressure 2.5bar, pre-screen nozzle aperture 1.5mm, first deformation hot box temperature 175°C, shaping hot box temperature 160°C, linear speed ratio of the first wire feed roller to the second wire feed roller 1.03 ,
  • the linear speed ratio of the third feeding roller and the second feeding roller is 1.1, the setting overfeed rate is 4%, the winding speed is 500m/min, and the winding overfeed rate is 2%.
  • the breaking strength of the black cotton-like fiber obtained after 60 days of continuous production is 2.2cN/dtex, the network degree is 85 pieces/m, and the CV value of breaking strength is 5.65%.
  • a method for preparing black cotton-like fibers is basically the same as in Example 1, except that the first wire guide and the tensioner are replaced with non-rollable godet rollers without the godet roller process.
  • the breaking strength of the black imitation cotton fiber that makes on the first day is 2.1cN/dtex, and network degree is 93/meter, and the CV value of breaking strength is 6.2%;
  • the first wire guide is guide wire
  • the wire guide wheel is in contact with the groove bottom of the first wire guide during the movement of the tow, and drives the first wire guide to rotate;
  • the material of the wire guide wheel is ceramic, the surface hardness of the groove bottom is 1800HV, and the friction coefficient between the groove bottom and the tow is 0.2;
  • the rim width of the godet wheel is 20mm, the outer diameter of the outer wheel is 9.4mm, and the inner diameter of the groove bottom is 6.2mm; contact; the tension of the tensioner is set to 9.2cN;
  • the process parameters are: pre-screen nozzle air pressure 2.6bar, pre-screen nozzle aperture 1.5mm, first deformation hot box temperature 178°C, shaping hot box temperature 152°C, linear speed ratio of the first wire feed roller to the second wire feed roller 1.03 , The linear speed ratio of the third feeding roller and the second feeding roller is 1.12, the shaping overfeed rate is 4.2%, the winding speed is 520m/min, and the winding overfeed rate is 2.2%.
  • the tension force of tow is 2.5cN when pre-networking;
  • the breaking strength of the black imitation cotton fiber that makes on the first day is 2.2cN/dtex, and network degree is 97/meter, and the CV value of breaking strength 5.05%;
  • the breaking strength of the black cotton-like fiber obtained after 60 days of continuous production is 2.1cN/dtex, the network degree is 89 pieces/m, and the CV value of breaking strength is 5.46%.
  • a kind of preparation method of black imitation cotton fiber adopts above-mentioned DTY texturizing process, wherein, the specifications of polyester POY and polyester FDY fiber are all 120dtex/96f, and carbon black content is 1.4wt%;
  • the first wire guide is wire godet , the tow is in contact with the bottom of the groove of the first wire guide during its movement, driving the first wire guide to rotate;
  • the material of the wire guide wheel is ceramic, the surface hardness of the bottom of the groove is 1880HV, and the friction coefficient between the bottom of the groove and the tow is 0.22;
  • the rim width of the godet wheel is 23mm, the outer diameter of the outer wheel is 10.2mm, and the inner diameter of the groove bottom is 7mm;
  • the tensioner is a magnetic tensioner; the tow is in contact with the groove bottom of the godet wheel attached to the tensioner during movement;
  • the tension of the tensioner is set to 8.7cN;
  • the process parameters are: pre-screen nozzle air pressure 2.8bar, pre-screen nozzle aperture 1.6mm, first deformation hot box temperature 184°C, shaping hot box temperature 155°C, linear speed ratio of the first wire feed roller to the second wire feed roller 1.04 , The ratio of the linear speed of the third feeding roller to the second feeding roller is 1.13, the setting overfeed rate is 4.5%, the winding speed is 565m/min, and the winding overfeed rate is 2.7%.
  • the breaking strength of the black cotton-like fiber obtained after 60 days of continuous production is 2.2cN/dtex, the network degree is 92 pieces/m, and the CV value of breaking strength is 5.86%.
  • the first wire guide is guide wire
  • the wire guide wheel is in contact with the groove bottom of the first yarn guide during the movement of the tow, and drives the first yarn guide to rotate;
  • the material of the wire guide wheel is ceramic, the surface hardness of the groove bottom is 2000HV, and the friction coefficient between the groove bottom and the tow is is 0.22;
  • the rim width of the godet wheel is 25mm, the outer diameter of the outer wheel is 10.7mm, and the inner diameter of the groove bottom is 7.4mm; contact; the tension of the tensioner is set to 7cN;
  • the process parameters are: pre-screen nozzle air pressure 2.9bar, pre-screen nozzle aperture 1.7mm, first deformation hot box temperature 190°C, shaping hot box temperature 160°C, linear speed ratio of the first wire feed roller to the second wire feed roller 1.04 , The ratio of the linear speed of the third feeding roller to the second feeding roller is 1.14, the shaping overfeed rate is 5%, the winding speed is 600m/min, and the winding overfeed rate is 3%.
  • the tension force of tow is 5.0cN when pre-networking;
  • the breaking strength of the black imitation cotton fiber that makes on the first day is 2.2cN/dtex, and network degree is 93/meter, and the CV value of breaking strength 5.25%;
  • the breaking strength of the black cotton-like fiber obtained after 60 days of continuous production is 2.1cN/dtex, the network degree is 87 pieces/m, and the CV value of breaking strength is 5.86%.

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  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
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Abstract

一种黑色仿棉纤维的制备方法，采用DTY加弹工艺，含有炭黑的涤纶POY和FDY纤维(1)依次经过第一导丝器(2)、导丝罗拉(3)、张力器(4)、第一喂丝罗拉(5)、预网络(6)、第二喂丝罗拉(7)、第一变形热箱(8)、冷却板(9)、假捻器(10)、第三喂丝罗拉(11)、中网络器(12)、定型热箱(13)、定型喂丝罗拉(14)、上油(15)、卷绕成型得到黑色仿棉纤维；第一导丝器(2)为导丝轮；丝束运动过程中与第一导丝器(2)的槽底接触，带动第一导丝器(2)转动；张力器(4)为磁力张力器；丝束运动过程中与张力器(4)所带导丝轮的槽底接触，丝束在与槽底接触前后所呈的劣角角度为140°～160°；张力器(4)的设定张力为7～10cN；第一喂丝罗拉(5)与第二喂丝罗拉(7)的线速度比值为1.03～1.04。该方法能够减少第一导丝器(2)的磨损，提高丝束网络度，并且没有散网。

Description

一种黑色仿棉纤维的制备方法 技术领域
本发明属于聚酯纤维技术领域，涉及一种黑色仿棉纤维的制备方法。
背景技术
涤纶是由对苯二甲酸(PTA)与乙二醇(EG)进行缩聚生产制得的聚对苯二甲酸乙二酯(PET)。涤纶是合成纤维的最大类属，其产量居所有化学纤维之首。目前市场主要品种有预取向丝POY、全牵伸丝FDY、拉伸变形丝DTY等。
涤纶预取向丝也称涤纶部分取向丝，是由高速纺丝(纺丝速度3000～3600m/min)得到的初生丝(亦即卷绕丝)。与一般的拉伸丝相比，其取向度低，结晶度低；而与常规纺丝得到的未拉伸丝(UDY)相比，其取向度高。20世纪70年代初，由于高速卷绕机的工业化生产，高速纺丝技术得到高速发展，并逐步实现工业化。由高速纺丝工艺得到的初生丝具有一定的取向度，可以直接进行拉伸变形来制得变形丝，从而缩短工艺流程。
全牵伸丝FDY是在POY高速纺丝中引入拉伸，将纺丝、拉伸和卷绕集为一体的一步法连续工艺制得的具有全取向结构的拉伸丝。FDY与POY相比，二者有共同的高取向，但FDY的结晶度比POY高。POY和FDY虽然有一定的取向度，但是与成品丝相比其性质仍然不稳定，不具有服用性能，必需通过后加工。后加工中90％以上是经拉伸变形工艺，制取拉伸变形丝DTY(俗称低弹丝)。涤纶低弹丝是以涤纶长丝为原料，利用纤维的热塑性，经过变形和热定型得到的高卷曲蓬松性能的新型纱。DTY长丝产品柔软，具有蓬松性，以DTY为原料的织物有较好的蓬松性、保暖性，一般可用于服饰、帐篷、箱包等。
目前通常以炭黑为色母粒对涤纶长丝进行着色，但是炭黑这类无机添加物会导致原料丝束粗糙，短时间内会将现有的第一导丝器磨损出凹槽，使导丝器的使用寿命降低，并且丝束与导丝器之间的磨损还会对丝束性能产生负面影响。
由于第一导丝器被磨损出凹槽，凹槽表面较为粗糙，会对丝束产生较大的阻力拉力，使得丝束在第一导丝器和第一喂丝罗拉之间产生很高的张力，该张力会被传导到第一喂丝罗拉和第二喂丝罗拉丝束上，导致丝束张力过大，使得网络喷嘴无法将丝束网络打牢，导致脱网，出现产品质量问题，使得产品无法生产。因此，需要对生产工艺进行优化来解决导丝器磨损高、丝束张力大的问题，使预网络更加稳定。
发明内容
本发明的目的是解决现有技术中存在的上述问题，提供一种黑色仿棉纤维的制备方法。
为达到上述目的，本发明采用的技术方案如下：
一种黑色仿棉纤维的制备方法，采用DTY加弹工艺，涤纶POY和涤纶FDY纤维依次经过第一导丝器、导丝罗拉、张力器、第一喂丝罗拉、预网络、第二喂丝罗拉、第一变形热箱、冷却板、假捻器、第三喂丝罗拉、中网络器、定型热箱、定型喂丝罗拉、上油、卷绕成型得到黑色仿棉纤维；
涤纶POY和涤纶FDY纤维中均含有炭黑；
所述第一导丝器为导丝轮；
丝束运动过程中与所述第一导丝器的槽底接触，带动所述第一导丝器转动；
所述张力器为磁力张力器，是一种通过磁场转换扭矩变化产生阻尼，无机械摩擦的张力控制装置，磁力张力器体型较小方便安装；丝束运动过程中与所述张力器所带的导丝轮的槽底接触；所述张力器的设定张力为7～10cN(通过张力器中的传感器进行调整，张力方向指向线束两端)，将第一导丝器由导丝辊替换为导丝轮后，虽然丝束的张力大大降低，但会导致丝束张力不易控制，张力不稳定，丝束的抖动严重，施加7～10cN的张力后，能够大大减少丝束的抖动；
所述第一喂丝罗拉与所述第二喂丝罗拉的线速度比值为1.03～1.04，形成一定的超喂比，便于预网络的形成。
作为优选的技术方案：
如上所述的一种黑色仿棉纤维的制备方法，所述第一导丝器的导丝轮轮缘宽度为20～25mm，导丝轮外轮外径为9.4～10.7mm，槽底内径为6～7.4mm。
如上所述的一种黑色仿棉纤维的制备方法，所述第一导丝器的材质为陶瓷，其槽底表面硬度为1500～2000HV(维氏硬度)，槽底与丝束间的摩擦系数为0.2～0.22(摩擦系数参考文章“高性能纤维的摩擦系数测试与分析”中的测试方法)。
如上所述的一种黑色仿棉纤维的制备方法，预网络时丝束的张力为2.5～5.0cN，连续进行DTY加弹一年后预网络时丝束的张力仍在该范围内。
如上所述的一种黑色仿棉纤维的制备方法，涤纶POY和涤纶FDY纤维中炭黑含量均为1.2～1.5wt％。
如上所述的一种黑色仿棉纤维的制备方法，炭黑的平均粒径为0.3～0.4μm。
如上所述的一种黑色仿棉纤维的制备方法，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，黑色仿棉纤维的线密度为232dtex。
如上所述的一种黑色仿棉纤维的制备方法，主要工艺参数为：预网喷嘴气压2.5～2.9bar，预网喷嘴孔径1.5～1.7mm，第一变形热箱温度175～190℃，定型热箱温度150～160℃，所述第三喂丝罗拉与所述第二喂丝罗拉的线速度比值(拉伸倍数)1.1～1.14，定型超喂率4.0～5.0％，卷绕速度500～600m/min，卷绕超喂率2.0～3.0％。
如上所述的一种黑色仿棉纤维的制备方法，所述黑色仿棉纤维的断裂强度为2.1～2.3cN/dtex(测试标准：GB/T 14344)，网络度为90～100个/米(测试标准：FZ/T 50001-2005)，断裂强度的CV值≤6.00％；
连续生产60天制得的所述黑色仿棉纤维的断裂强度、网络度以及断裂强度的CV值的变化率均不高于10％；即与第1天生产所述黑色仿棉纤维时相比，连续两个月生产所述黑色仿棉纤维后，得到的所述黑色仿棉纤维的断裂强度和网络度下降幅度均不超过10％，断裂强度的CV值的上升幅度不超过10％。本发明的原理如下：
以炭黑为色母粒对涤纶长丝进行着色会使丝束表面不光滑，由于现有加弹工艺中导丝器无法绕轴旋转，丝束与导丝器之间为滑动摩擦，导致在对涤纶长丝进行DTY加弹时，3～5天内会将第一导丝器磨损，由于第一导丝器短时间被磨损后产生凹槽，丝束从该凹槽经过时产生的阻力拉力较大，导致丝束在经过第一导丝器时的张力变大，可变大到20～25cN，由于第一喂丝罗拉的握持是两个圆外圈接触压住握持，存在握持不充分，不能达到100％握持，存在打滑，则第一导丝器处20～25cN的张力会使预网络时丝束张力升高到6～8cN(如果握持充分的话，丝束张力只会受到超喂比的影响，而一旦握持不充分，那么第一喂丝罗拉前的丝束张力就会对第一喂丝罗拉后的丝束张力产生影响，第一喂丝罗拉前的丝束张力过大就会使第一喂丝罗拉后的丝束张力升高)，丝束张力过大会使得预网络的网络喷嘴无法将丝束网络打牢，导致脱网，这会使得丝束在后续织造过程中，由于网络少，且由于双组分复合丝的物性不一样，双丝抱合性差，导致织造过程中断头多，且在布面存在毛结疙瘩，导致布面不平整，严重影响了产品性能。
本发明将原有的第一导丝器替换为导丝轮，能够使丝束与导丝器之间的摩擦力由滑动摩擦变为滚动摩擦，不仅能够减少导丝器的磨损，还能够大幅降低丝束在经过第一导丝器时的张力。
由于第一导丝器被替换为导丝轮，因此丝束的张力大大降低，但是替换为导丝轮后，丝束张力不易控制，张力不稳定，无法将张力控制在一个稳定的范围，并且导丝轮会导致丝束张力过小，丝束将会严重抖动，产生飘丝，使得生产无法进行。因此本发明通过磁力张力器以及导丝罗拉来给丝束施加一定的张力，磁力张力器和导丝罗拉放置在第一导丝器与第一喂丝罗拉之间，且磁力张力器距离第一喂丝罗拉更近，并且丝束在与磁力张力器所带导丝轮槽底接触前后所呈的角度在一定范围，丝束在移动过程中会对导丝轮产生压力，使角度有变大的趋势，因此磁力张力器产生的阻尼会与丝束产生的压力形成反作用力，用来保持这个角度大小的稳定；该反作用力对于丝束就形成了丝束的张力。导丝罗拉能够稳定由于张力减小而导致的抖丝现象，这对于通过张力器来控制张力给予了很大的帮助。
本发明通过将磁力张力器的张力设定在7～10cN的范围，能够大大减少丝束的抖动，使其保持稳定，张力过大或过小均不利于预网络的稳定。
本发明还通过设定第一喂丝罗拉与第二喂丝罗拉线速度比值(超喂比)为1.03～1.04，形成超喂，使丝束在预网络阶段的张力处于2.5～5.0cN(尽管第一喂丝罗拉存在握持不充分的现象，会使丝束在第一 喂丝罗拉前的张力影响到丝束第一喂丝罗拉后的张力，但是由于将导丝器替换为导丝轮，以及通过磁力张力器来控制线束张力，这就使得丝束在第一喂丝罗拉前的张力大大降低，这也大大降低了通过控制超喂比来控制张力的工艺难度，完全能够实现使丝束在预网络阶段的张力保持在2.5～5.0cN范围内)，能够稳定打网，不会产生散网，并且也不会产生飘丝。
有益效果：
(1)本发明的一种黑色仿棉纤维的制备方法，能够提高丝束网络度，并且没有散网，这会使后续制得的含炭黑涤纶低弹丝织物布面平整，不易断头；
(2)本发明的一种黑色仿棉纤维的制备方法，采用的DTY加弹工艺能够为丝束提供适当并且稳定的张力；
(3)本发明的一种黑色仿棉纤维的制备方法，制得的黑色仿棉纤维性能较好；
(4)本发明的一种黑色仿棉纤维的制备方法，能够减少第一导丝器的磨损，避免资源损耗。
附图说明
图1为本发明的制备工艺流程图；
图2为本发明的导丝轮的剖面结构示意图；
其中，1-涤纶POY和涤纶FDY纤维，2-第一导丝器，3-导丝罗拉，4-张力器，5-第一喂丝罗拉，6-预网络，7-第二喂丝罗拉，8-第一变形热箱，9-冷却板，10-假捻器，11-第三喂丝罗拉，12-中网络器，13-定型热箱，14-定型喂丝罗拉，15-上油。
具体实施方式
下面结合具体实施方式，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
本发明实施例中第一天制得的黑色仿棉纤维的断裂强度、网络度和断裂强度的CV值是指第一天整天生产得到的黑色仿棉纤维的性能的平均值；连续生产60天后制得的黑色仿棉纤维的断裂强度、网络度和断裂强度的CV值是指第60天整天生产得到的黑色仿棉纤维的性能的平均值。
采用DTY加弹工艺制备黑色仿棉纤维的流程为：如图1所示，含有平均粒径为0.3～0.4μm的炭黑的涤纶POY和涤纶FDY纤维1依次经过第一导丝器2、导丝罗拉3、张力器4、第一喂丝罗拉5、预网络6、第二喂丝罗拉7、第一变形热箱8、冷却板9、假捻器10、第三喂丝罗拉11、中网络器12、定型热箱13、定型喂丝罗拉14、上油15、卷绕成型得到黑色仿棉纤维。
实施例1
一种黑色仿棉纤维的制备方法，采用上述DTY加弹工艺，其中，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，炭黑含量均为1.2wt％；第一导丝器为导丝轮，丝束运动过程中与第一导丝器的槽底接触，带动第一导丝器转动；导丝轮的材质为陶瓷，槽底表面硬度为1500HV，槽底与丝束间的摩擦系数为0.2；如图2所示，导丝轮的轮缘宽度为20mm，外轮外径为9.4mm，槽底内径为6mm；张力器为磁力张力器；丝束运动过程中与张力器所带导丝轮的槽底接触；张力器的张力设定为10cN；
工艺参数为：预网喷嘴气压2.5bar，预网喷嘴孔径1.5mm，第一变形热箱温度175℃，定型热箱温度160℃，第一喂丝罗拉与第二喂丝罗拉的线速度比值1.03，第三喂丝罗拉与第二喂丝罗拉的线速度比值1.1，定型超喂率4％，卷绕速度500m/min，卷绕超喂率2％。
采用上述工艺进行连续生产，预网络时丝束的张力为3.7cN；第一天制得的黑色仿棉纤维的断裂强度为2.3cN/dtex，网络度为90个/米，断裂强度的CV值为5.15％；
连续生产60天后制得的黑色仿棉纤维的断裂强度为2.2cN/dtex，网络度为85个/米，断裂强度的CV值为5.65％。
对比例1
一种黑色仿棉纤维的制备方法，基本同实施例1，不同之处仅在于将第一导丝器和张力器均替换为无法滚动的导丝辊，且不经过导丝罗拉的工序。第一天制得的黑色仿棉纤维的断裂强度为2.1cN/dtex，网络度为93个/米，断裂强度的CV值为6.2％；连续生产10天后制得的黑色仿棉纤维的断裂强度为1.8cN/dtex，网络度为74个/米，断裂强度的CV值为7.6％，60天后已无法生产。将实施例1与对比例1进行对比可以看出，黑色仿棉纤维的断裂强度、网络度以及断裂强度的CV值均有较大幅度的变化，这是因为第一导丝器的磨损对纤维的品质影响较大。
实施例2
一种黑色仿棉纤维的制备方法，采用上述DTY加弹工艺，其中，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，炭黑含量均为1.3wt％；第一导丝器为导丝轮，丝束运动过程中与第一导丝器的槽底接触，带动第一导丝器转动；导丝轮的材质为陶瓷，槽底表面硬度为1800HV，槽底与丝束间的摩擦系数为0.2；导丝轮的轮缘宽度为20mm，外轮外径为9.4mm，槽底内径为6.2mm；张力器为磁力张力器；丝束运动过程中与张力器所带导丝轮的槽底接触；张力器的张力设定为9.2cN；
工艺参数为：预网喷嘴气压2.6bar，预网喷嘴孔径1.5mm，第一变形热箱温度178℃，定型热箱温度152℃，第一喂丝罗拉与第二喂丝罗拉的线速度比值1.03，第三喂丝罗拉与第二喂丝罗拉的线速度比值1.12，定型超喂率4.2％，卷绕速度520m/min，卷绕超喂率2.2％。
采用上述工艺进行连续生产，预网络时丝束的张力为2.5cN；第一天制得的黑色仿棉纤维的断裂强度为2.2cN/dtex，网络度为97个/米，断裂强度的CV值为5.05％；
连续生产60天后制得的黑色仿棉纤维的断裂强度为2.1cN/dtex，网络度为89个/米，断裂强度的CV值为5.46％。
实施例3
一种黑色仿棉纤维的制备方法采用上述DTY加弹工艺，其中，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，炭黑含量均为1.4wt％；第一导丝器为导丝轮，丝束运动过程中与第一导丝器的槽底接触，带动第一导丝器转动；导丝轮的材质为陶瓷，槽底表面硬度为1880HV，槽底与丝束间的摩擦系数为0.22；导丝轮的轮缘宽度为23mm，外轮外径为10.2mm，槽底内径为7mm；张力器为磁力张力器；丝束运动过程中与张力器所带导丝轮的槽底接触；张力器的张力设定为8.7cN；
工艺参数为：预网喷嘴气压2.8bar，预网喷嘴孔径1.6mm，第一变形热箱温度184℃，定型热箱温度155℃，第一喂丝罗拉与第二喂丝罗拉的线速度比值1.04，第三喂丝罗拉与第二喂丝罗拉的线速度比值1.13，定型超喂率4.5％，卷绕速度565m/min，卷绕超喂率2.7％。
采用上述工艺进行连续生产，预网络时丝束的张力为4.5cN；第一天制得的黑色仿棉纤维的断裂强度为2.3cN/dtex，网络度为100个/米，断裂强度的CV值为5.32％；
连续生产60天后制得的黑色仿棉纤维的断裂强度为2.2cN/dtex，网络度为92个/米，断裂强度的CV值为5.86％。
实施例4
一种黑色仿棉纤维的制备方法，采用上述DTY加弹工艺，其中，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，炭黑含量均为1.5wt％；第一导丝器为导丝轮，丝束运动过程中与第一导丝器的槽底接触，带动第一导丝器转动；导丝轮的材质为陶瓷，槽底表面硬度为2000HV，槽底与丝束间的摩擦系数为0.22；导丝轮的轮缘宽度为25mm，外轮外径为10.7mm，槽底内径为7.4mm；张力器为磁力张力器；丝束运动过程中与张力器所带导丝轮的槽底接触；张力器的张力设定为7cN；
工艺参数为：预网喷嘴气压2.9bar，预网喷嘴孔径1.7mm，第一变形热箱温度190℃，定型热箱温度160℃，第一喂丝罗拉与第二喂丝罗拉的线速度比值1.04，第三喂丝罗拉与第二喂丝罗拉的线速度比值1.14，定型超喂率5％，卷绕速度600m/min，卷绕超喂率3％。
采用上述工艺进行连续生产，预网络时丝束的张力为5.0cN；第一天制得的黑色仿棉纤维的断裂强度为2.2cN/dtex，网络度为93个/米，断裂强度的CV值为5.25％；
连续生产60天后制得的黑色仿棉纤维的断裂强度为2.1cN/dtex，网络度为87个/米，断裂强度的CV值为5.86％。

Claims (9)

  1. 一种黑色仿棉纤维的制备方法，采用DTY加弹工艺，其特征在于：涤纶POY和涤纶FDY纤维依次经过第一导丝器、导丝罗拉、张力器、第一喂丝罗拉、预网络、第二喂丝罗拉、第一变形热箱、冷却板、假捻器、第三喂丝罗拉、中网络器、定型热箱、定型喂丝罗拉、上油、卷绕成型得到黑色仿棉纤维；
    涤纶POY和涤纶FDY纤维中均含有炭黑；
    所述第一导丝器为导丝轮；
    丝束运动过程中与所述第一导丝器的槽底接触，带动所述第一导丝器转动；
    所述张力器为磁力张力器；丝束运动过程中与所述张力器所带导丝轮的槽底接触；所述张力器的张力设定为7～10cN；
    所述第一喂丝罗拉与所述第二喂丝罗拉的线速度比值为1.03～1.04。
  2. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，所述第一导丝器的导丝轮轮缘宽度为20～25mm，导丝轮外轮外径为9.4～10.7mm，槽底内径为6～7.4mm。
  3. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，所述第一导丝器的材质为陶瓷，其槽底表面硬度为1500～2000HV，槽底与丝束间的摩擦系数为0.2～0.22。
  4. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，预网络时丝束的张力为2.5～5.0cN。
  5. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，涤纶POY和涤纶FDY纤维中炭黑含量均为1.2～1.5wt％。
  6. 根据权利要求5所述的一种黑色仿棉纤维的制备方法，其特征在于，炭黑的平均粒径为0.3～0.4μm。
  7. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，涤纶POY和涤纶FDY纤维的规格均为120dtex/96f，黑色仿棉纤维的线密度为232dtex。
  8. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，主要工艺参数为：预网喷嘴气压2.5～2.9bar，预网喷嘴孔径1.5～1.7mm，第一变形热箱温度175～190℃，定型热箱温度150～160℃，所述第三喂丝罗拉与所述第二喂丝罗拉的线速度比值1.1～1.14，定型超喂率4.0～5.0％，卷绕速度500～600m/min，卷绕超喂率2.0～3.0％。
  9. 根据权利要求1所述的一种黑色仿棉纤维的制备方法，其特征在于，所述黑色仿棉纤维的断裂强度为2.1～2.3cN/dtex，网络度为90～100个/米，断裂强度的CV值≤6.00％；
    连续生产60天制得的所述黑色仿棉纤维的断裂强度、网络度以及断裂强度的CV值的变化率均不高于10％。
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