HYBRID YARN AND DEVICE AND METHOD FOR PRODUCING A HYBRID YARN

Abstract

A hybrid yarn, and associated system and method of making, are provided wherein a first continuous yarn is formed as a multi-filament yarn and a second continuous yarn is formed as a crimped yarn consisting of thermoplastic fibers in a parallel thread sheet. The parallel thread sheet has a plurality of crimped continuous threads next to one another in one plane. The continuous threads are formed from as a collection of a plurality of continuous filaments.

Claims

1-19. (canceled)

20. A hybrid yarn, comprising: a first continuous yarn formed as a multi-filament yarn; a second continuous yarn formed as a crimped yarn consisting of thermoplastic fibers in a parallel thread sheet, the parallel thread sheet comprising a plurality of crimped continuous threads next to one another in one plane; and wherein each of the continuous threads comprises a collection of a plurality of continuous filaments.

21. The hybrid yarn according to claim 20, wherein the multi-filament yarn comprises carbon with lithe undulation.

22. The hybrid yarn according to claim 20, wherein the multi-filament yarn of the first continuous yarn comprises from 6,000 to 60,000 filaments having a tensile strength of at least 500 kg/mm2.

23. The hybrid yarn according to claim 20, wherein the second continuous yarn comprises any one or combination of a polyethylene, a polypropylene, a polyamide, a polyester, or a polyaryletherketone, and has a titer of 20 to 500 dtex.

24. The hybrid yarn according to claim 20, wherein the parallel thread sheet of the second continuous yarn comprises a plurality of core yarns of a non-crimped core fiber and crimped wrapping fibers, the non-crimped core fibers being of a same material as the crimped wrapping fibers.

25. The hybrid yarn according to claim 20, wherein the multi-filament yarn of the first continuous yarn has 12,000 filaments

26. A system for producing a hybrid yarn having at least two continuous yarns, the system comprising: an unwinding device that unwinds a first continuous yarn from a bobbin, the unwinding device comprising a brake; a tension sensor configured to measure tension in the first continuous yarn; a relief spreader configured to spread out the first continuous yarn to form of a compact band; a first pair of clamping rollers, and a second pair of clamping rollers; a flow spreader arranged between the first and second pairs of clamping rollers to form a spread-out first continuous yarn; a plurality of bobbins are arranged on a first creel, each of the bobbins supplying a crimped continuous thread to form a second continuous yarn; a comb arranged with the plurality of bobbins to form the second continuous yarn as a parallel thread sheet from the continuous threads supplied by the bobbins; a laying roller configured to deposit the spread-out first continuous yarn with the parallel thread sheet forming the second continuous yarn, wherein the parallel thread sheet is laid over the spread-out continuous yarn to form a thread sheet; at least two deflectors arranged such that the laying roller is wrapped by the spread-out first continuous yarn and the parallel thread sheet forming the second continuous yarn by at least 30 degrees; a pair of pressure rollers configured to press the thread sheet into the hybrid yarn; and a winding device configured to wind the hybrid yarn to form a bobbin.

27. The system according to claim 26, further comprising a heating section upstream of the winding device configured to link the first and second continuous yarns.

28. The system according to claim 26, further comprising a second creel with a plurality of bobbins each supplying a crimped continuous thread to form a second parallel thread sheet, the second creel arranged such that on the laying roller a first side of the spread-out first continuous yarn is covered by the parallel thread sheet and an opposite side of the spread-out first continuous yarn is covered by the second parallel thread sheet.

29. The system according to claim 29, further comprising a spray head configured and heating section upstream of the winding device to apply an additive to the hybrid yarn.

30. A method for producing a hybrid yarn, the method comprising; unwinding a first continuous yarn in the form of a multi-filament yarn from a bobbin; measuring a yarn tension of the first continuous yarn with a tension sensor and controlling the yarn tension with a brake configured with the bobbin; guiding the first continuous yarn to a first pair of clamping rollers via a relief spreader and spreading rollers; downstream of the first pair of clamping rollers, guiding the first continuous yarn as a spread-out first continuous yarn to a second pair of clamping rollers via a flow spreader connected to a vacuum source; unwinding a crimped continuous thread from a plurality of bobbins mounted on a creel, the crimped continuous threads forming a second continuous yarn; with a comb, forming the crimped continuous threads into a parallel thread sheet wherein the crimped continuous threads are aligned parallel to a course of the spread-out first continuous yarn; superimposing the spread-out first continuous yarn and the parallel hread sheet on a laying roller to form a thread sheet; guiding the thread sheet over at least two deflectors to a pair of pressure rollers; with pressure rollers, pressing the thread sheet to form the hybrid yarn; and winding the hybrid yarn in a winding device.

31. The method according to claim 30, further comprising guiding the hybrid yarn through a heating section after the pressure rollers and before the winding device.

32. The method according to claim 30, further comprising regulating a thread tension of the thread sheet to optimize a linking of the first continuous yarn with the second continuous yarn.

33. The method according to claim 30, further comprising spraying the hybrid yarn with an additive and passing the sprayed hybrid yarn through a heating section downstream of the pair of pressure rollers.

34. The method according to claim 30, further comprising, at the laying roller, depositing a second parallel thread sheet of the crimped continuous fibers onto an opposite side of the spread-out first continuous yarn.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The invention is described below on the basis of an exemplary embodiment and explained in more detail with the drawings.

[0049] FIG. 1 shows schematically a first embodiment of the method according to the invention;

[0050] FIG. 2 shows schematically a second embodiment of the method according to the invention; and

[0051] FIG. 3 shows schematically a third embodiment of the method according to the invention.

DETAILED DESCRIPTION

[0052] Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.

[0053] FIG. 1 shows schematically the method for producing the hybrid yarn in a first embodiment. A first continuous yarn 1 is unwound from a bobbin 3, while the bobbin 3 rotates in the direction of the arrow. The first continuous yarn 1, which is a reinforcing yarn in the form of a band consisting of a large number of filaments, is passed through a tension sensor 5 downstream of the bobbin 3. The tension sensor 5 measures the tension in the first continuous yarn 1 and acts on a brake 4 of the bobbin 3 via a controller, such that the first continuous yarn 1 is unwound from the bobbin 3 at a constant tension. As a result, the first continuous yarn 1 runs through a relief spreader 6 and subsequent spreading rollers 7 and then reaches a first pair of clamping rollers 8. The first pair of clamping rollers 8 is the actual conveying element, which unwinds the first continuous yarn 1 from the bobbin 3 and pulls it through the tension sensor 5, the relief spreader 6, and the spreading rollers 7.

[0054] The first continuous yarn 1 is guided to a second pair of clamping rollers 9 via a flow spreader 10. The second pair of clamping rollers 9 is used to determine the depth of immersion of the first continuous yarn 1 in the flow spreader 10. In the flow spreader 10, the first continuous yarn 1 is guided through an air flow which is generated with the aid of a vacuum source 11. The air flow is guided from top to bottom through the first continuous yarn 1 in the form of a band. This has the effect that the first continuous yarn 1, which has already been partially spread out by the relief spreader 6 and the spreading rollers 7, is spread out further and is at least partly separated into its filaments. Owing to the arrangement of the air flow, any foreign bodies that are still present or protective layers or coatings that have been broken up by the previous spreading are sucked off. Downstream of the second pair of clamping rollers 9, the now spread-out first continuous yarn 12 is guided to a laying roller 17.

[0055] A large number of continuous threads are drawn off from a large number of bobbins 14, which are arranged in a creel 13, and arranged over a comb 15 to form a thread sheet 16 of the second continuous yarn 2. The thread sheet 16 of the second continuous yarn 2 is then deposited on the laying roller 17 and thus on the spread-out first continuous yarn 12 or on and next to or between the filaments of the spread-out first continuous yarn 12. On the laying roller 17, the filaments of the spread-out first continuous yarn 12 are combined with the thread sheet 16 of the second continuous yarn 2 to form a thread sheet 19 of a hybrid yarn. The thread sheet 19 of the hybrid yarn is deflected via two deflectors 18 downstream of the laying roller 17, such that the laying roller 17 is wrapped around as little as possible. The thread sheet 19 of the hybrid yarn then reaches a pair of pressure rollers 20. The pair of pressure rollers 20 consists of a lower pressure roller 21 and an upper pressure roller 22, the upper pressure roller 22 being equipped with an actuator for adjusting the pressure. The thread sheet 16 of the second continuous yarn 2 and the spread-out first continuous yarn 12 are pulled over the laying roller 17 by the pair of pressure rollers 20. At the nip point of the pair of pressure rollers 20, the actual hybrid yarn 23 is formed from the thread sheet 19 of the hybrid yarn and is then wound in a winding device 24 to form a bobbin 26. The bobbin 26 is rotated in the direction of the arrow by a drive 25 for winding the hybrid yarn 23.

[0056] FIG. 2 shows schematically the method for producing the hybrid yarn in a second embodiment. The second embodiment differs from the first embodiment in a further method step for forming the hybrid yarn after passing through the pair of pressure rollers 20 and upstream of the winding device 24. The formation of the thread sheet 19 of the hybrid yarn, starting from the first continuous yarn 1 removed from a bobbin 3, and from the continuous threads of the second continuous yarn 2 removed from bobbins 14, is identical to the embodiment according to FIG. 1.

[0057] After leaving the pair of pressure rollers 20, the hybrid yarn 23 is sprayed with an additive 29. The powdered additive 29 is applied to the surface of the hybrid yarn 23 by a spray head 27. The hybrid yarn 23 is then guided through a heating section 28 to the winding device 24. The applied additive 29 is melted in the heating section 28 and connects the continuous threads of the second continuous yarn 2 within the hybrid yarn 23. This improves the cohesion of the hybrid yarn 23 during subsequent processing.

[0058] In a third embodiment of the method for producing the hybrid yarn 23, as can be seen from FIG. 3, a further feed of a thread sheet 16 of the second continuous yarn 2 is provided. The method for producing the hybrid yarn 23 in the third embodiment is identical, in the execution of the method steps and the arrangement of the individual devices, with the first embodiment according to FIG. 1 with the exception of the second introduced creel 13. By introducing a second creel 13 with bobbins 14 arranged therein, a second thread sheet 16 of the second continuous yarn 2 can be formed over a second comb 15 and applied to the laying roller 17. In this case, this second thread sheet 16 is guided onto the laying roller 17 on a side of the spread-out first continuous yarn 12 opposite the first thread sheet 16. The spread-out first continuous yarn 12 is thus introduced between the two thread sheets 16. By setting the combs 15, an optimal distribution of the second continuous yarn 2 over the width of the spread-out first continuous yarn 12 can be achieved.

[0059] The present invention is not limited to the embodiments shown and described. Modifications within the scope of the claims are possible, as is a combination of the features, even if these are shown and described in different embodiments.

LIST OF REFERENCE SIGNS

[0060] 1 First continuous yarn

[0061] 2 Second continuous yarn

[0062] 3 Bobbin of first continuous yarn

[0063] 4 Brake

[0064] 5 Tension sensor

[0065] 6 Relief spreader

[0066] 7 Spreading rollers

[0067] 8 First pair of clamping rollers

[0068] 9 Second pair of clamping rollers

[0069] 10 Flow spreader

[0070] 11 Vacuum source

[0071] 12 Spread-out first continuous yarn

[0072] 13 Creel

[0073] 14 Bobbin of second continuous yarn

[0074] 15 Comb

[0075] 16 Thread sheet of second continuous yarns

[0076] 17 Laying roller

[0077] 18 Deflector

[0078] 19 Thread sheet of hybrid yarn

[0079] 20 Pair of pressure rollers

[0080] 21 Lower pressure roller

[0081] 22 Upper pressure roller

[0082] 23 Hybrid yarn

[0083] 24 Winding device

[0084] 25 Drive

[0085] 26 Bobbin of hybrid yarn

[0086] 27 Spray head

[0087] 28 Heating section

[0088] 29 Additive