METHOD FOR MANUFACTURING FLAME-RETARDANT BULKY FIBER WITHOUT FLAME RETARDANT ON FULLY-DRAWN YARN (FDY) MACHINE

Abstract

A method for manufacturing a flame-retardant bulky fiber without a flame retardant on a fully-drawn yarn (FDY) machine is provided. The flame-retardant bulky fiber is formed by winding a plurality of spiral yarns arranged in the same direction; and the yarns are polyester yarns with a fineness of 0.52 DPF to 80 DPF. The method includes the following steps: slicing and drying a polyester masterbatch; spinning through a spinning die, and cooling by side blowing; cooling and oiling; drawing by a first hot roller; drawing and shaping by a second hot roller; and winding. The present disclosure can manufacture a flame-retardant bulky fiber on an FDY machine, which has the same effect as drawn textured yarn (DTY) manufactured by a texturing machine. Moreover, without being added with any chemical flame retardant, the flame-retardant bulky fiber of the present disclosure can reach the flame-retardant standard of home textiles.

Claims

1. A flame-retardant bulky fiber, wherein the flame-retardant bulky fiber is formed by winding a plurality of spiral yarns arranged in the same direction; and the plurality of spiral yarns are polyester yarns with a fineness of 0.52 DPF to 80 DPF.

2. The flame-retardant bulky fiber according to claim 1, comprising 18 to 576 yarns for the winding.

3. The flame-retardant bulky fiber according to claim 1, wherein the flame-retardant bulky fiber does not comprise a flame retardant.

4. The flame-retardant bulky fiber according to claim 1, wherein the flame-retardant bulky fiber is manufactured by one-step spin-drawing on an FDY machine at a drawing ratio of 1.6 to 2.6.

5. A method for manufacturing the flame-retardant bulky fiber according to claim 1 on an FDY machine, comprising the following steps: S1: slicing and drying a polyester masterbatch; S2: spinning through a spinning die, and then cooling by side blowing; S3: cooling and oiling; S4: drawing by a first hot roller, wherein the first hot roller has a temperature of 80° C. to 88° C. and a speed of 1,850 m/min to 1,980 m/min; S5: drawing and shaping by a second hot roller, wherein the second hot roller has a temperature 30° C. to 50° C. higher than the temperature of the first hot roller and a speed of 3,600 m/min to 5,600 m/min; and S6: winding.

6. The method according to claim 5, wherein in S1, the drying is conducted at 150° C. to 170° C. for 7 h to 10 h.

7. The method according to claim 5, wherein in S2, the cooling by side blowing is conducted at a wind speed controlled at 0.55 m/s to 0.7 m/s and a wind temperature controlled at 16° C. to 25° C.

8. The method according to claim 5, wherein in step S3, the oiling is conducted at an oiling rate of 0.8% to 1.5%.

9. The method according to claim 5, wherein a ratio of the speed of the second hot roller to the speed of the first hot roller is (1.6-2.6):1.

10. A method of using the flame-retardant bulky fiber according to claim 1, a home textile is manufactured by using the flame-retardant bulky fiber.

11. The method according to claim 5, wherein the flame-retardant bulky fiber comprises 18 to 576 yarns for the winding.

12. The method according to claim 5, wherein the flame-retardant bulky fiber does not comprise a flame retardant.

13. The method according to claim 5, wherein the flame-retardant bulky fiber is manufactured by one-step spin-drawing on the FDY machine at a drawing ratio of 1.6 to 2.6.

14. The method according to claim 10, wherein the flame-retardant bulky fiber comprises 18 to 576 yarns for the winding.

15. The method according to claim 10, wherein the flame-retardant bulky fiber does not comprise a flame retardant.

16. The method according to claim 10, wherein the flame-retardant bulky fiber is manufactured by one-step spin-drawing on an FDY machine at a drawing ratio of 1.6 to 2.6.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Other features, objectives, and advantages of the present disclosure will become more apparent by reading the detailed description of non-limiting examples with reference to the following accompanying drawings.

[0041] FIG. 1 is a schematic diagram of a manufacturing process of the flame-retardant bulky fiber of the present disclosure; and

[0042] FIG. 2A is a schematic diagram of a bundle structure of the flame-retardant bulky fiber of the present disclosure, and FIG. 2B is a schematic diagram of a bundle structure of the ordinary FDY fiber.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0043] The present disclosure is described in detail below with reference to examples. The following examples will help those skilled in the art to further understand the present disclosure, but do not limit the present disclosure in any way. It should be noted that those of ordinary skill in the art can further make several modifications and improvements without departing from the idea of the present disclosure. These all fall within the protection scope of the present disclosure.

Example 1 Manufacturing of Flame-Retardant Bulky Polyester Fiber 300 Dtex/96F

[0044] A method for manufacturing a flame-retardant bulky fiber without a flame retardant on an FDY machine was provided in this example. The manufacturing process was shown in FIG. 1 and included the following steps:

[0045] (1) Slicing: A polyester masterbatch was sliced.

[0046] (2) Drying: Polyester masterbatch slices were dried at 165° C. for 9 h.

[0047] (3) Spinning through a spinning die: The FDY machine adopted a Φ105 spinning screw and a spinning die Φ90-48-*0.8 (0.14*0.24). As a flat spinning die with a linear cross section is conducive to the linear deformation of fibers after being drawn at a high strength, a flat spinning die was used for spinning in this example. When the spinning was conducted, temperatures of a first zone, a second zone, a third zone, a fourth zone, and a fifth zone of the Φ105 spinning screw were controlled at 275° C., 281° C., 286° C., 286° C., and 283° C., respectively. As a spinning speed should be controlled at 3,600 r/min to 4,000 r/min, which is also a factor to determine a drawing ratio, a spinning speed of 4,000 r/min was selected in this example.

[0048] (4) Cooling by blowing: After the spinning was conducted through the spinning die, obtained fibers were cooled by side blowing. During the side blowing, a wind temperature should be controlled at 16° C. to 25° C. and preferably at 20° C. to 22° C. A wind speed was controlled at 0.6 m/s and a wind temperature was controlled at 21° C. in this example. The cooling method of side blowing and the appropriate wind speed and wind temperature are some of the key factors to realize the manufacturing of the flame-retardant bulky fiber without a flame retardant on an FDY machine.

[0049] (5) Oiling: The fibers were oiled by an oiler at a rotational speed of 30 r/min and an oiling rate of 0.8% to 1.5%.

[0050] (6) Rolling by a first hot roller: A temperature of the first hot roller was set to 82° C., and a speed VGR1 of the first hot roller was set to 1,924 m/min.

[0051] (7) Rolling by a second hot roller: A temperature of the second hot roller was set to 116° C., and a speed VGR2 of the second hot roller was set to 4,040 m/min.

[0052] (8) Winding: A winding speed was set to 4,000 r/min.

[0053] In the above manufacturing process, a drawing stage is the key to the linear deformation. The finished product FDY is obtained by two-stage drawing (including spinning die drawing between the hot roller GR and the spinning die and roller drawing between the first hot roller and the second hot roller), setting, and winding. The drawing ratio of the drawing in the present disclosure refers to a speed ratio of the first hot roller to the second hot roller (the hot rollers have different rotational speeds due to different diameters, which are generally expressed as a linear speed (m/min)).

[0054] Keys for the manufacturing of a flame-retardant bulky fiber without a flame retardant on an FDY machine in the present disclosure include: 1) controlling a drawing ratio at 1.6 to 2.6; 2) controlling a temperature of the first hot roller at 80° C. to 88° C.; and 3) controlling a temperature difference (referring to a value by which the temperature of the second hot roller is higher than the temperature of the first hot roller) at 30° C. to 50° C. A structural diagram of the manufactured flame-retardant bulky fiber without a flame retardant is shown in FIG. 2 (a), which is completely different from that of the ordinary FDY fiber (FIG. 2 (b)). The flame-retardant bulky fiber of the present disclosure is formed by winding a plurality of spiral yarns arranged in the same direction (the yarns can be polyester yarns with a fineness of 0.52 DPF to 80 DPF). The number of wound yarns is actually determined by the number of holes in the spinning die, which can be 18 to 576.

[0055] A crystallinity is used to indicate a proportion of crystalline regions in a polymer. A crystallinity of a polymer varies widely, generally from 30% to 85%. For the same material, the higher the crystallinity, the higher the melting point. Crystallization is an orderly arrangement of molecular chains, and at a melting point, all molecular assembly structures are destroyed to form molecular chains. Generally, the higher the crystallinity, the more regular the arrangement of molecular chains. Therefore, at a high crystallinity, a high temperature is required to destroy the molecular assembly structures, resulting in a high melting point. At present, common methods for testing crystallinity include density-gradient test, X-ray diffraction (XRD), differential scanning calorimetry (DSC), infrared spectrometry, hydrolysis analysis, formylation analysis, deuterium exchange analysis, and the like. The present disclosure used the density-gradient test to test the crystallinity of the flame-retardant bulky fiber. In order to verify the importance of the temperatures of the hot roller and the temperature difference between the hot rollers for the manufacturing of the flame-retardant bulky fiber without a flame retardant on the FDY machine, the temperatures of and the temperature difference between the hot rollers were adjusted on the basis of the aforementioned operating parameters in this example. Crystallinity results of the manufactured flame-retardant bulky fibers were shown in Table 1:

TABLE-US-00001 TABLE 1 Influence of the temperatures of and the temperature difference between the hot rollers on crystallinity Crystallinity Temperature Temperature obtained by of the of the Temperature density- Fiber first hot second hot difference gradient variety roller/° C. roller/° C. (° C.) test/% Flame- 70 100 30 19.6576 retardant 70 120 50 28.5565 bulky fiber 75 120 45 27.2617 300 dtex/ 80 105 25 24.6349 96 F. 80 110 30 40.0478 80 120 40 45.0362 82 116 34 46.1824 85 130 45 45.3785 88 138 50 44.5013 90 130 40 29.3470

[0056] In order to further verify the importance of the drawing ratio for the manufacturing of the flame-retardant bulky fiber without a flame retardant on the FDY machine, the drawing ratio was adjusted on the basis of the aforementioned operating parameters in this example, which was specifically as follows: 1) a speed VGR1 of the first hot roller was set to 1,924 m/min and a speed VGR2 of the second hot roller was set to 2,308 m/min, in which case, a corresponding drawing ratio was 1.2; and 2) a speed VGR1 of the first hot roller was set to 1,910 m/min and a speed VGR2 of the second hot roller was set to 9,550 m/min, in which case, a corresponding drawing ratio was 3.5. In the case where a drawing ratio was 1.2, the manufactured fiber did not have the flame retardant effect; and in the case where a drawing ratio was 3.5, the manufactured fiber did not have both the bulky effect and the structure shown in FIG. 2 (a). The fibers obtained in the above two cases were quite different from the flame-retardant bulky fiber of the present disclosure. Further, in this example, the drawing ratio was further adjusted on the basis of the aforementioned operating parameters, and it was found that the flame-retardant bulky fiber of the present disclosure could be obtained when the drawing ratio was between 1.6 and 2.6.

Example 2 Manufacturing of Flame-Retardant Bulky Polyester Fiber 240 Dtex/48F

[0057] A method for manufacturing a flame-retardant bulky fiber without a flame retardant on an FDY machine was provided in this example. The manufacturing process was shown in FIG. 1 and included the following steps:

[0058] (1) Slicing: A polyester masterbatch was sliced.

[0059] (2) Drying: Polyester masterbatch slices were dried at 150° C. for 8 h.

[0060] (3) Spinning through a spinning die: The FDY machine adopted a Φ120 spinning screw and a spinning die Φ90-48-*0.8 (0.14*0.24). A flat spinning die was also used for spinning in this example. When the spinning was conducted, temperatures of a first zone, a second zone, a third zone, a fourth zone, and a fifth zone of the Φ120 spinning screw were controlled at 263° C., 267° C., 272° C., 274° C., and 276° C., respectively. A spinning speed was controlled at 3,600 r/min in this example.

[0061] (4) Cooling by blowing: After the spinning was conducted through the spinning die, obtained fibers were cooled by side blowing at a wind speed controlled at 0.65 m/s and a wind temperature controlled at 20° C.

[0062] (5) Oiling: The fibers were oiled by an oiler at a rotational speed of 30 r/min and an oiling rate of 1.0%.

[0063] (6) Rolling by a first hot roller: A temperature of the first hot roller was set to 85° C., and a speed VGR1 of the first hot roller was set to 1,924 m/min.

[0064] (7) Rolling by a second hot roller: A temperature of the second hot roller was set to 130° C., and a speed VGR2 of the second hot roller was set to 3,078 m/min.

[0065] (8) Winding: A winding speed was set to 4,000 r/min.

[0066] A structural diagram of the manufactured flame-retardant bulky fiber without a flame retardant is shown in FIG. 2 (a), which is formed by winding a plurality of spiral yarns arranged in the same direction. Similarly, a crystallinity of the flame-retardant bulky fiber in this example was determined by a density-gradient test, which was 48.3764%, indicating that the flame-retardant bulky fiber without a flame retardant has prominent flame retardance.

Example 3 Manufacturing of Flame-Retardant Bulky Polyester Fiber 300 Dtex/96F

[0067] A method for manufacturing a flame-retardant bulky fiber without a flame retardant on an FDY machine was provided in this example. The manufacturing process was shown in FIG. 1 and included the following steps:

[0068] (1) Slicing: A polyester masterbatch was sliced.

[0069] (2) Drying: Polyester masterbatch slices were dried at 165° C. for 9 h.

[0070] (3) Spinning through a spinning die: The FDY machine adopted a Φ105 spinning screw and a spinning die Φ90-48-*0.8 (0.14*0.24). As a flat spinning die with a linear cross section is conducive to the linear deformation of fibers after being drawn at a high strength, a flat spinning die was used for spinning in this example. When the spinning was conducted, temperatures of a first zone, a second zone, a third zone, a fourth zone, and a fifth zone of the Φ105 spinning screw were controlled at 275° C., 281° C., 286° C., 286° C., and 283° C., respectively. A spinning speed was controlled at 3,850 r/min.

[0071] (4) Cooling by blowing: After the spinning was conducted through the spinning die, obtained fibers were cooled by side blowing at a wind speed controlled at 0.65 m/s and a wind temperature controlled at 23° C. The cooling method of side blowing and the appropriate wind speed and wind temperature are some of the key factors to realize the manufacturing of the flame-retardant bulky fiber without a flame retardant on an FDY machine.

[0072] (5) Oiling: The fibers were oiled by an oiler at a rotational speed of 30 r/min and an oiling rate of 1.2%.

[0073] (6) Rolling by a first hot roller: A temperature of the first hot roller was set to 82° C., and a speed VGR1 of the first hot roller was set to 1,924 m/min.

[0074] (7) Rolling by a second hot roller: A temperature of the second hot roller was set to 116° C., and a speed VGR2 of the second hot roller was set to 5,002 m/min.

[0075] (8) Winding: A winding speed was set to 4,500 r/min.

[0076] A structural diagram of the manufactured flame-retardant bulky fiber without a flame retardant is also shown in FIG. 2 (a), which is formed by winding a plurality of spiral yarns arranged in the same direction. Similarly, a crystallinity of the flame-retardant bulky fiber in this example was determined by a density-gradient test, which was 51.0692%, indicating that the flame-retardant bulky fiber without a flame retardant has prominent flame retardance.

[0077] Furthermore, the flame-retardant bulky fibers without a flame retardant manufactured in Examples 1, 2, and 3 were tested according to the American Home Textile Flame Retardant Standard ASTM 16 CFR 1630, and it was found that the fiber products of the present disclosure can meet the flame retardant standard requirements without any flame-retardant treatment.

Example 4 Use of Flame-Retardant Bulky Polyester Fibers

[0078] The flame-retardant bulky fiber without a flame retardant manufactured by the present disclosure can be used in the manufacturing of garments, carpets, and other home textiles. Use of the flame-retardant bulky fiber without a flame retardant manufactured in Example 1 in a carpet was provided in this example, including the following steps:

[0079] 1) the flame-retardant bulky fiber was used as a main material to weave a carpet surface;

[0080] 2) a substrate was prepared; and

[0081] 3) the carpet surface was adhered, fitted, or stitched on the substrate to obtain the carpet.

[0082] In summary, the present disclosure can manufacture a flame-retardant bulky fiber on an FDY machine, which has the same effect as DTY manufactured by a texturing machine. Moreover, without being added with any chemical flame retardant, the flame-retardant bulky fiber of the present disclosure can reach the flame-retardant standard of home textiles. The flame-retardant bulky fiber also has the characteristics of high brightness, no pilling, smoothness, and softness. Fabrics using the flame-retardant bulky fiber have prominent bulkiness, elasticity, and flame retardance.

[0083] The specific examples of the present disclosure are described above. It should be understood that the present disclosure is not limited to the above specific implementations, and a person skilled in the art can make various variations or modifications within the scope of the claims without affecting the essence of the present disclosure.