Method and apparatus for spinning and texturing a multifilament composite yarn

Abstract

A method and an apparatus for spinning and texturing a multifilament composite yarn. The composite yarn is formed from a plurality of yarn components, which are spun, cooled, drawn, and textured in parallel relationship. To obtain physical properties that are adapted to the quality characteristics of the yarn components, the invention provides for drawing at least one of the yarn components separately and independently of the other yarn components before texturing. To this end, a plurality to separate feed roll systems are provided, with at least one of the feed roll systems being associated to the one of the yarn components, and with the one yarn component being drawn by the feed roll system separately and independently of the other yarn components.

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of international application PCT/EP2003/008810, filed 8 Aug. 2003, and which designates the U.S. The disclosure of the referenced application is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates to a method for spinning and texturing a multifilament composite yarn as well as an apparatus for carrying out the method.

A generic method as well as a generic apparatus for spinning and texturing a multifilament composite yarn are disclosed in EP 0 784 109 A2 and corresponding U.S. Pat. No. 6,119,320.

For producing a textured composite yarn by the method disclosed in the referenced patents, a plurality of yarn components are initially spun from a thermoplastic melt by a spinning means, then cooled, and separately pretreated in parallel side-by-side relationship. The yarn components are jointly withdrawn from the spinning means by a withdrawal system, and drawn before undergoing texturing. For texturing the component yarns, the latter are textured jointly or parallel in side-by-side relationship and subsequently combined to form a composite yarn.

The known method is directed to changing the appearance of the composite yarn by a separate compacting step, essentially by separately entangling or separately texturing the differently dyed yarn components. However, such visual properties represent only a part of the properties of the yarn which are desired for further processing. For the use and application of fabrics produced from such composite yarns, such as, for example, carpets, the physical properties, such as strength and elongation take priority over visual properties. In this respect, the known method and the known apparatus play only a subordinate role in the production of qualitatively superior composite yarns.

Likewise, the method disclosed in EP 0 861 931 A2 and U.S. Pat. No. 6,442,923, attempts to influence in particular the visual properties of a composite yarn formed from yarn components by separate and individual treatment of yarn components. In this process, freshly spun and drawn yarn components, or drawn individual yarns that are unwound from a package, are separately treated in different ways by entangling, texturing, or false twisting, and combined to a composite yarn.

It is an object of the invention to provide a generic method for spinning and texturing a multifilament composite yarn as well as a generic apparatus for carrying out the method, which permit producing qualitatively superior textured composite yarns with optimized physical and visual properties.

A further object of the invention is to provide a method and an apparatus, which permit treating parallel spun yarn components or yarns with greatest flexibility until they are wound.

SUMMARY OF THE INVENTION

The invention is based on the knowledge that after spinning, yarn components that are parallel spun from a basic polymer, may have an individual molecular structure as a result of adding different additives, for example, different dyes. When advancing and drawing the yarn components jointly, this individual molecular structure will lead to different physical properties, in particular different strengths. This is where the invention comes into play, in that at least one of the yarn components is drawn separately and independently of the other yarn components before being textured. It was thus found that in the production of a composite yarn from an individual polypropylene yarn that had been dyed blue, and a second undyed polypropylene yarn, different draw ratios lead to respectively maximum strengths with simultaneously the least residual elongations in the yarn components. Thus, the blue dyed yarn component required a draw ratio of 1:2.5, and the undyed yarn component required drawing at the ratio of 1:3.5. With that, the invention permits the purposeful influencing of the physical properties of the yarn components in a manner that it is possible to produce a composite yarn of maximum strength, while having simultaneously a minimal residual elongation.

To obtain during the spinning of the yarn components a drawing that is adapted to the characteristics of the yarn component, an advantageous further development proposes to withdraw a yarn component during spinning separately and independently of the other yarn components at a withdrawal speed that differs from the withdrawal speeds of the other yarn components.

In a preferred embodiment of the method, wherein to each yarn component a plurality of separate feed roll systems are associated, which withdraw the yarn components during the spinning separately and advance them separately for drawing, it is possible to adjust on each of the yarn components the maximum strength with the least residual elongation. With that a very uniform and qualitatively superior crimp can be realized in each of the yarn components after texturing.

To improve the visual properties of the composite yarn, it is possible and advantageous to entangle the yarn components separately before drawing by means of a pressurized fluid.

To obtain an as uniform and superior crimp as possible when texturing the yarn components after spinning, it is preferred to apply the stuffer box principle in the texturing step. To this end, it is possible to compress the yarn components after drawing either separately or jointly to form a yarn plug in a stuffer box chamber. Because of the great strength of the yarn components, it is possible to reach very great yarn plug densities, which result in an intensive formation of loops and curls in the individual filaments of the yarn components and, thus, in an intensive crimp.

Before winding the composite yarn, the latter is formed preferably by entangling or texturing the yarn components. The choice in which way the yarn components are combined to the composite yarn is essentially determined by the desired visual properties of the composite yarn. For example, to obtain in the case of a multicolor yarn a distinct, accentuated mixed color, it is preferred to produce the composite yarn after separately texturing the yarn components by entangling.

To carry out the method, a withdrawal system is provided which is formed by a plurality of feed roll systems, with at least one feed roll system being associated to one of the yarn components. The yarn component being drawn by the one feed roll system is thus drawn separately and independently of the other yarn components.

The feed roll system associated to the one yarn component is made for separate operation and control, so that an individual adjustment is possible for withdrawing and drawing the yarn component.

The highest flexibility for carrying out the method is ensured by an advantageous further development of the apparatus, wherein the feed roll systems are associated to the yarn components such that each of the yarn components is withdrawn and drawn independently of adjacent yarn components.

In this arrangement, the feed roll systems can be operated or controlled individually or in groups.

For texturing the yarn components, the texturing means is formed preferably by a feed nozzle and a stuffer box chamber cooperating with the feed nozzle. The feed nozzle is preferably operated with a hot conveying medium, so that the yarn components or the formed yarn plug undergo a thermal treatment at the same time. For cooling the yarn plugs emerging from the stuffer box chamber, a cooling unit is provided which cools the yarn plugs by means of a cooling medium.

The method and the apparatus of the invention are also suited for producing a composite yarn, whose yarn components are spun from different polymers. In this connection, it is possible to spin basically all known polymer materials, such as, for example, polyamide, polyester, or polypropylene.

In the case that the composite yarn is produced from feed yarn packages, it is advantageous to apply the method of the invention wherein the yarns are parallel spun from a polymer melt, cooled, and drawn before being textured, separately and independently of one another by a plurality of feed roll systems that are associated to the yarns. After drawing, the yarns are separately textured and each wound to a package. It is also preferred to use the method for the production of identical yarns. The individual treatment of the yarn components until they are wound is however used preferably in the case of different quality of the yarns.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following, the methods of the invention are described in greater detail by means of several embodiments of the apparatus according to the invention with reference to the attached Figures, in which:

FIG. 1 is a schematic view of a first embodiment of the apparatus according to the invention;

FIG. 2 is a schematic view of a second embodiment of the apparatus according to the invention;

FIGS. 3 and 4 are schematic views of some embodiments of a withdrawal means of the apparatus according to the invention; and

FIG. 5 is a schematic view of a further embodiment of an apparatus for carrying out the method of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The apparatus as shown in FIG. 1 comprises a spinning means 1 that connects to one or more melt producers (not shown). The spinning means 1 includes a heated spin beam 2, which mounts in side-by-side relationship a plurality of spinnerets 3.1-3.3. The spinnerets 3.1-3.3 each comprise on their underside a plurality of spin holes, through which a polymer melt which is supplied to each of the spinnerets 3.1-3.3 flows. The melt is thus extruded under pressure to form a plurality of groups of individual filaments.

Downstream of the spin beam 2, a cooling shaft 4 is provided, through which the groups of extruded filaments advance, so that the filaments emerging at approximately the melt point are cooled. To this end, the cooling shaft 4 could connect, for example, to an air flow system, which blows cooling air substantially transversely toward the filaments. After cooling the filaments, the filament groups associated to respective spinnerets 3.1-3.3 are combined to form a yarn component 6.1-6.3 by yarn guides 5.1-5.3 at the outlet of the cooling shaft 4.

Downstream of the spinning means 1 is a withdrawal means 10 for withdrawing the yarn components 6.1-6.3 from the spinnerets 3.1-3.3. The withdrawal means 10 is formed by a plurality of feed roll systems 14.1-14.6 which are associated to each of the yarn components 6.1-6.3. Thus, the yarn component 6.1 is withdrawn from the spinning means 1 by feed roll system 14.1, the yarn component 6.2 by feed roll system 14.2, and the yarn component 6.3 by feed roll system 14.3. The feed roll systems 14.1-14.6 are each formed by a driven godet and an associated companion roll, which are looped by the respective yarn component several times. In particular, the drives of the feed roll systems 14.1-14.3 are controllable independently of one another, so that it is possible to adjust a withdrawal speed that is adapted to the particular yarn component.

To be able to draw the yarn components 6.1-6.3 in full, the feed roll systems 14.1-14.3 are each followed by an additional feed roll system 14.4-14.6. Thus, the yarn component 6.1 advances through feed roll systems 14.1 and 14.4, the yarn component 6.2 through feed roll systems 14.2 and 14.5, and the yarn component 6.3 through feed roll systems 14.3 and 14.6. The feed roll systems 14.4-14.6 are operated preferably likewise independently of one another by separate drive units. In the case that all yarn components 6.1-6.3 are removed by the withdrawal means 10 at the same yarn speed, the feed roll systems 14.4-14.6 can be activated preferably via a common control unit. In this case, it would also be possible to combine the individual drives of the feed roll systems 14.4-14.6 to a group drive. In the cases, in which the withdrawal means 10 removes the yarn components 6.1-6.3 at different yarn speeds, for example, to realize visual effects on a composite yarn, the drives of the feed roll systems 14.4-14.6 are separately operated and controlled.

To pretreat the yarn components 6.1-6.3, a pretreatment means 8 is provided between the spinning means 1 and the withdrawal means 10. The pretreatment means 8 is formed by yarn lubrication units 7.1-7.3 associated to each of the yarn components 6.1-6.3 and subsequent entanglement nozzles 9.1-9.3. In this arrangement, a lubricant is applied to each of the yarn components 6.1-6.3 independently of the others. Subsequently, the filaments of the yarn components undergo an entanglement, each in its associated entanglement nozzle 9.1-9.3. With that a yarn cohesion is essentially produced for the further treatment of the yarn components 6.1-6.3.

The further treatment of the yarn components 6.1-6.3 occurs downstream of the withdrawal means 10 in a texturing means 11 and an aftertreatment means 12. In the embodiment of FIG. 1, the texturing means 11 is formed by a feed nozzle 15 and a stuffer box chamber 16 cooperating therewith. The feed nozzle 15 connects to a source of pressure, which supplies a conveying medium to the feed nozzle 15. The conveying medium draws the yarn components 6.1-6.3 into the feed nozzle 15 and subsequently compresses them to a yarn plug in the stuffer box chamber 16. This causes the yarn components 6.1-6.3 to intermingle in part. Subsequently, the yarn plug which is preferably produced by a heated conveying medium, advances to a cooling unit 17, and undergoes cooling. To treat the textured yarn components 6.1-6.3, the aftertreatment means 12 downstream of the texturing means 11 comprises a first withdrawal godet 18.1 downstream of the cooling unit 17. Downstream of the withdrawal godet 18.1 is a combining means 19 which finally intermingles the yarn components 6.1-6.3 to form a composite yarn 21. In the present embodiment, the combining means 19 is likewise formed by an entanglement nozzle. An additional withdrawal godet 18.2 removes the composite yarn 21 from the combining means 19 and advances it to a takeup means 13. The takeup means 13 winds the composite yarn 21 to a package 20.

In the embodiment of the device according to the invention as illustrated in FIG. 1, the spinnerets 3.1-3.3 are used to spin three yarn components 6.1-6.3 in a parallel side-by-side relationship. The yarn components 6.1-6.3 may be produced from different polymer compositions. For example, each of the yarn components 6.1-6.3 could include a different dye, an admixture of a different additive, or different basic polymers. To obtain as much as possible uniform physical properties despite the different material qualities of the yarn components 6.1-6.3, the yarn components 6.1-6.3 are withdrawn from the spinnerets 3.1-3.3 by their respective feed roll systems 14.1-14.3 at an individually adjusted withdrawal speed. They are subsequently drawn by the feed rolls systems 14.4-14.6 downstream thereof. With that, a drawing can occur that is adapted to each of the yarn components 6.1-6.3 for the purposes of purposefully and separately influencing and adjusting desired physical properties, such as strength and elongation.

After having been drawn, the yarn components 6.1-6.3 are jointly textured and combined to the composite yarn 21. The composite yarn 21 that is produced by the method of the invention distinguishes itself by great uniformity in its physical properties. It is thus possible and advantageous to produce high-strength yarns. Depending on desire and requirements for visual properties, it is possible to operate with a plurality of treatment steps.

FIG. 2 illustrates a further embodiment of a device according to the invention for carrying out the method of the invention. The embodiment is essentially identical to the foregoing embodiment, so that the foregoing description is herewith incorporated by reference and that only differences are described. Components having identical functions have been provided with identical numerals.

In the embodiment of FIG. 2, the spinning means 1, the pretreatment means 8, the withdrawal means 10, the aftertreatment means 12, and the takeup means 13 are constructed identical to the foregoing embodiment.

For texturing the yarn components 6.1-6.3, the texturing means 11 is formed by separate feed nozzles with associated stuffer box chambers. Thus, the texturing means 11 is composed of feed nozzles 15.1-15.3 and their associated stuffer box chambers 16.1-16.3. Downstream of the stuffer box chambers 16.1-16.3 are cooling units 17.1-17.3. The feed nozzles 15.1-15.3 and the stuffer box chambers 16.1-16.3 can be arranged in separate housings or in a common housing. Likewise, the cooling units 17.1-17.3 can be replaced with one structural unit, along which three parallel yarn plugs advance. Essential in the embodiment shown in FIG. 2 is that after being individually drawn, the yarn components 6.1-6.3 are separately textured. Besides the optimized physical properties, it is thus possible to produce in the composite yarn 21 in particular also special visual properties. After separately texturing the yarn components 16.1-16.3, same are jointly removed from the respective yarn plugs by withdrawal godet 18.1 and advanced to the combining means 19 for forming the composite yarn 21.

The withdrawal means of the embodiments shown in FIGS. 1 and 2 are exemplary in their arrangement and construction. Thus, it is possible to combine the withdrawal means in the illustrated embodiments in any way to realize a draw ratio that is adapted to the yarn components.

FIG. 3 illustrates a further embodiment of a withdrawal means, as could be used, for example, in the device of FIG. 1 or 2. In the case of this embodiment, the feed roll systems 14.1 and 14.3 are associated to the yarn component 6.1, whereas the yarn components 6.2 and 6.3 advance together over the feed roll systems 14.2 and 14.4. It is thus possible to advance and draw the yarn component 6.1 independently of the yarn components 6.2 and 6.3. The yarn components 6.2 and 6.3 are jointly advanced and drawn by the feed roll systems 14.2 and 14.4. Likewise, in this embodiment, the feed roll systems 14.1-14.4 are formed by a driven godet and an associated guide roll. Associated to each of the driven godets is an individual drive unit which is independently controllable.

FIG. 4 illustrates a further embodiment of a withdrawal means, as could be used, for example, in the devices of FIGS. 1 and 2. In this embodiment, the feed roll system 14.1 withdraws the yarn component 6.1. The yarn components 6.2 and 6.3 are jointly withdrawn by the feed roll system 14.2. The further drawing of the yarn components 6.1-6.3 then proceeds jointly by feed roll system 14.3. The feed roll systems 14.1-14.3 are operated at different circumferential speeds, so that the yarn component 6.1 undergoes a different drawing than the other yarn components 6.2 and 6.3. The yarn components 6.1-6.3 are then jointly advanced by the feed roll system 14.3 to the texturing unit downstream thereof.

FIG. 5 illustrates an embodiment of an apparatus, which permits carrying out the method of the invention for producing parallel spun yarns. Other than in the foregoing embodiments, after spinning, each of the yarn components 6.1 and 6.2 is treated, textured, aftertreated, and wound independently of the other. To this end, the takeup means 13 comprises a plurality of winding positions 22.1 and 22.2. In each of the winding positions 22.1 and 22.2, a yarn component 6.1 and 6.2 is each wound to a package 20.1 and 20.2. Between the spinning means 1 and the takeup means 13, a pretreatment means 8, withdrawal means 10, texturing means 11, and aftertreatment means 12 are arranged. In this arrangement, each means preferably comprises for each yarn component 6.1 and 6.2 identical treatment means and units. Essential is that each of the treatment means and units arranged in the path of the yarn components 6.1-6.2 is independently and separately controllable to enable an individual treatment of the yarn components 6.1 and 6.2. After the individual treatment steps, the yarn components 6.1 and 6.2 form yarns 21.1 and 21.2 which are wound at an identical winding speed to the packages 20.1 and 20.2.

Associated to each of the yarn components are, a lubrication means 7.1, 7.2, an entanglement nozzle 9.1, 9.2, a first feed roll system 14.1, 14.3, a second feed roll system 14.2, 14.4, a feed nozzle 15.1, 15.2 with a stuffer box chamber 16.1, 16.2, a cooling unit 17.1, 17.2, a first withdrawal godet 18.1, 18.3, an entanglement nozzle 9.1, 9.2, as well as a second withdrawal godet 18.2, 18.4 one following the other in the path of the advancing yarn. An arrangement of this type is particularly suited for producing different yarns 21.1, 21.2 within a spinning apparatus. When spinning the yarns, it is then possible to take into account in particular individually adjusted withdrawal speeds and draw ratios.

The described embodiments for carrying out the method of the invention are exemplary in their arrangement and selection of the treatment units. Additional pretreatment or aftertreatment steps and means may be introduced to be able to perform, for example, additional treatments on the yarn components before or after texturing them, or to carry out additional treatments on the composite yarn. Likewise, the type and the construction of the texturing means is exemplary. To adjust defined crimps, the yarn components may also be textured, each with different parameters. In the case of separate texturing, it is also possible to apply different texturing methods. The separate adjustment of the draw parameters on the yarn components provides a high flexibility in the production of textured composite yarns.

Likewise, the configuration of the feed roll system in the illustrated embodiments is exemplary. It would thus be possible to construct all or part of the feed roll systems with respectively two driven godets. Both godets of a feed roll system could be operated at the same or different circumferential speeds. In addition, one or both godets of a feed roll system could include heating means to be able to perform a thermal treatment on the yarns.

Claims

1. A method of spinning and texturing a multifilament composite yarn which is composed of a plurality of individual yarn components, comprising the steps of

melt spinning a plurality of individual multifilament yarn components so as to advance parallel to each other, while cooling and drawing the individual yarn components, and including drawing at least one of the individual yarn components separately and independently from the other individual yarn components, then

texturing the individual yarn components separately or jointly,

gathering together the individual yarn components to form a composite yarn, and

winding the composite yarn into a package.

2. The method of claim 1, wherein the melt spinning step includes withdrawing the yarn components from respective spinnerets, and wherein the step of separately and independently drawing at least one of the yarn components includes withdrawing the at least one of the yarn components at a withdrawal speed which is different from the withdrawal speeds of the other individual yarn components.

3. The method of claim 1 wherein a plurality of feed roll systems are associated with each of the individual yarn components by which the individual yarn components are separately advanced for the purpose of being drawn.

4. The method of claim 1, wherein before being drawn, the individual yarn components are separately entangled by means of a pressurized fluid.

5. The method of claim 1, wherein after having been drawn, the individual yarn components are each separately compressed to a yarn plug in separate stuffer box chambers for the purpose of being textured.

6. The method of claim 1, wherein after having been drawn, the individual yarn components are jointly compressed to a yarn plug in a stuffer box chamber for the purpose of being textured.

7. The method of claim 1, wherein the composite yarn is formed by entangling or by texturing the individual yarn components.

8. An apparatus for spinning and texturing a multifilament component yarn, comprising

a melt spinning device for melt spinning a plurality of individual multifilament yarn components,

a withdrawal system for withdrawing and drawing the individual yarn components,

a texturing device for texturing the individual yarn components,

a combining device for gathering the individual yarn components to form a composite yarn,

a take-up device for winding the composite yarn into a package,

wherein the withdrawal system comprises a plurality of separate feed roll systems, with at least one of the feed roll systems being associated to one of the yarn components so that the one yarn component is drawn separately and independently of the other individual yarn components.

9. The apparatus of claim 8, wherein the at least one feed roll system is constructed for separate operation and control.

10. The apparatus of claim 8 wherein the feed roll systems are associated to the individual yarn components such that each of the individual yarn components is withdrawn and drawn independently of adjacent individual yarn components.

11. The apparatus of claim 10, wherein the feed roll systems are constructed to be operated and controlled individually or in groups.

12. The apparatus of claim 8 wherein the texturing device comprises a feed nozzle and a stuffer box chamber cooperating with the feed nozzle.

13. The apparatus of claim 12, wherein downstream of the stuffer box chamber a cooling unit extends, by which a yarn plug emerging from the stuffer box chamber can be cooled.

14. The apparatus of claim 8, wherein the combining device is formed by an entanglement unit, in which the individual yarn components are entangled with one another by means of a pressurized fluid.

15. A method for spinning and texturing a plurality of yarns, comprising the steps of melt spinning parallel yarns from a polymer melt and then cooling and drawing the yarns, and wherein the yarns are then separately textured and wound to a package, and wherein during the drawing step the yarns are drawn separately and independently of one another by a plurality of feed roll systems associated with the yarns, with the feed roll systems being constructed to be operated and controlled individually or in groups.