Method to form yarn via film fiberizing spinning

Abstract

A method to form yarn via film fiberizing spinning belongs to a textile technical field. A film cutting device is arranged behind each drafting system on a ring frame, whose cut resistance apron and cutting roller engage with each other to form a cutting zone to cut and fiberize the film to get belt-like multi-filaments. Then the multi-filament formed passes through the first, second and third drafting zones in sequence for drawing, in such a manner that the multi-filament molecular orientation and crystallization are improved. After being drafted, the multi-filaments are twisted into yarn by ring spinning, which provides a novel high-efficient and short-processing way of producing yarns of nano-micro fibers using films instead of conventional nano-spun fibers such as electro- and centrifugal spun fibers, thereby breaking restriction of low bulk and low-speed production of nano-spun fibers and integrating the film industry with the textile industry.

Claims

1. A method to form yarn via film fiberizing spinning, comprising steps of: arranging a film cutting device behind a drafting system on a ring frame, wherein the drafting system comprises a rear roller (8), a rear rubber roller (7), a middle roller (11), a middle rubber roller (10), a front roller (14), and a front rubber roller (13); the film cutting device comprises a bearing roller (16), an unwinding roller (4) and a cutting roller (5); a cut resistance apron (3) is wrapped onto the unwinding roller (4); loop blades, which are arranged in parallel, are located on the cutting roller (5) circumference; the cut resistance apron (3) corresponds to cutter edges of the loop blades located on the cutting roller (5); a cutting zone is formed between the cut resistance apron (3) and the cutting roller (5); centers of the cutting zone, the rear rubber roller (7), the middle rubber roller (10) and the front rubber roller (13) are in a same plane; the rear rubber roller (7) and the rear roller (8) of the drafting system engage with each other to form a rear roller nip; a first drafting zone is formed between the cutting zone and the rear roller nip; a filament guider (6) is provided in the first drafting zone; the middle roller (11) and the middle rubber roller (10) of the drafting system engage with each other to form a middle roller nip; a second drafting zone is formed between the rear roller nip and the middle roller nip; a first heater (9) is provided in the second drafting zone; a heating groove of the first heater (9) is parallel to an axis of the rear roller nip and an axis of the middle roller nip; the front roller (14) and the front rubber roller (13) engage with each other to form a front roller nip; a third drafting zone is formed between the middle roller nip and the front roller nip; a second heater (12) is provided in the third drafting zone; a heating groove of the second heater (12) is parallel to the axis of the middle roller nip and an axis of the front roller nip; during spinning, placing a film roll (1) between the bearing roller (16) and the unwinding roller (4), wherein films unwound from the film roll (1) enter the cutting zone formed between the cut resistance apron (3) and the cutting roller (5); the film cutting device cuts and fiberizes the films to form belt-like multi-filaments which are evenly paved before entering the first drafting zone, wherein the multi-filaments get a primary drawing; after the primary drawing, the multi-filaments outputting from the rear roller nip via the filament guider (6) enter the second drafting zone, wherein the multi-filaments heated in the heating groove of the first heater (9) get a secondary drawing; after the secondary drawing the multi-filaments outputting from the middle roller nip enter the third drafting zone, wherein the multi-filaments heated in the heating groove of the second heater (12) get a main drawing; after the main drawing, the multi-filaments outputting from the front roller nip are converged and twisted to form a yarn, subsequently the yarn passes through a pig-tail guider (15) of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin.

2. The method to form the yarn via the film fiberizing spinning, as recited in claim 1, wherein the cut resistance apron (3) is made of ultra-high-strength polyethylene, aramid, or rubber sufficient to interact with the loop blades.

3. The method to form the yarn via the film fiberizing spinning, as recited in claim 1, wherein a distance between cutter edges of adjacent loop blades is ranged from 0.1 mm to 3 mm.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 is a sketch view of working principles of the present invention.

(2) FIG. 2 is a sketch view of a film cutting device during working.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(3) Referring to the drawings, a method to form yarn via film fiberizing spinning according to the present invention is further illustrated.

(4) Please refer to the drawings.

(5) The method to form yarn via film fiberizing spinning comprises steps of: arranging a film cutting device behind each drafting system on a ring frame, wherein the drafting system comprises a rear roller 8, a rear rubber roller 7, a middle roller 11, a middle rubber roller 10, a front roller 14, and a front rubber roller 13; the film cutting device comprises a bearing roller 16, an unwinding roller 4 and a cutting roller 5; separating rods 2 are provided between the bearing roller 16 and the unwinding roller 4, wherein each pair of the separating rods 2 correspond to the rear rubber roller 7 of each drafting system on the ring frame, so as to effectively limit films unwound from a film roll 1 into each drafting system on the ring frame; a cut resistance apron 3 made of ultra-high-strength polyethylene, aramid, or super high-strength rubber is wrapped onto the unwinding roller 4; loop blades, which are arranged in parallel, are located on the cutting roller 5 circumference, wherein a distance between cutter edges of adjacent loop blades is ranged from 0.1 mm to 3 mm; the shorter the distance between the cutter edges is, the thinner the belt-like multi-filaments formed by cutting and drafting will be; the cut resistance apron 3 corresponds to cutter edges of the loop blades located on the cutting roller 5; a cutting zone is formed between the cut resistance apron 3 and the cutting roller 5, whose width is no more than widths of corresponding rear, middle and front roller nips; the cutting zone center and the rear rubber roller 7 center, the middle rubber roller 10 center and the front rubber roller 13 center are in a same plane; a filament guider 6 is provided between the rear rubber roller 7 and the cutting roller 5, whose guiding tunnel is flat; the rear rubber roller 7 and the rear roller 8 of the drafting system engage with each other to form a rear roller nip; a first drafting zone is formed between the cutting zone and the rear roller nip; a filament guider 6 is provided in the first drafting zone; an extended line of an input end of a guiding tunnel of the filament guider 6 is tangent with the cutting area; an extended line of an output end of the guiding tunnel of the filament guider 6 is tangent with the rear rubber roller 7 at the rear roller nip; the middle roller 11 and the middle rubber roller 10 of the drafting system engage with each other to form a middle roller nip; a second drafting zone is formed between the rear roller nip and the middle roller nip; a first heater 9 is provided in the second drafting zone; a heating groove of the first heater 9 is parallel to an axis of the rear roller nip and an axis of the middle roller nip; the front roller 14 and the front rubber roller 13 engage with each other to form a front roller nip; a third drafting zone is formed between the middle roller nip and the front roller nip; a second heater 12 is provided in the second drafting zone; a heating groove of the second heater 12 is parallel to the axis of the middle roller nip and an axis of the front roller nip; the first heater 9 and the second heater 12 may adopts heaters disclosed in Chinese patent Iron spinning device, publishing No. CN201234734, published May 27, 2009, or other heating forms such as resistance wires; when an iron spinning device is used, the first heater 9 and the second heater 12 are externally connected to a 24-36 v low-voltage safety power supply through wires;

(6) during spinning, placing a film roll 1 between the bearing roller 16 and the unwinding roller 4, and between a pair of the separating rods 2, which means that both sides of the film roll 1 has one of the separating rods 2; wherein the films are organic polymer films, inorganic films, or organic-inorganic hybrid films; a width of the films are smaller than a width of the cutting zone, a thickness of the films are smaller than 1 mm; a smaller thickness of the films enables a thinner filament of the belt-like multi-filaments; the first heater 9 and the second heater 12 are externally connected to the safety power supply for heating internal walls of the heating grooves of the first heater 9 and the second heater 12 to 60-240 C.; when the films are the organic-inorganic hybrid films, the heating grooves of the first heater 9 and the second heater 12 are not heated, or the internal walls of the heating grooves of the first heater 9 and the second heater 12 are only heated to 60 C., so as to fully stretch and draw the belt-like multi-filaments after film fiberizing; when the films are the organic polymer films with an obvious glass-transition temperature, a larger thickness of the films means a higher glass-transition temperature, requiring a higher heating temperature, and vice versa; a higher drafting rate of the drafting zone requires a higher heating temperature, which is conducive to progressive thermal high-ratio drafting; wherein films unwound from the film roll 1 enter the cutting zone formed between the cut resistance apron 3 and the unwinding roller 4; in the cutting zone, the film cutting device cuts and fiberizes the films to form belt-like multi-filaments which are evenly paved before entering the first drafting zone, wherein the multi-filaments get a primary drawing for primary stretching and extending before a high rate drafting; after the primary drawing, the multi-filaments outputting from the rear roller nip via the filament guider 6 enter the second drafting zone, wherein the multi-filaments heated in the heating groove of the first heater 9 get a secondary drawing, wherein an inner consolidation structure of the polymer filaments with the obvious glass transition temperature become loosened so that each filament of the multi-filaments is in a high-elastic state and stretched by the secondary drawing, as a result, each filaments become attenuated and get inner molecular orientation and crystallization improvements; after the secondary drawing the multi-filaments outputting from the middle roller nip enter the third drafting zone, wherein the multi-filaments heated in the heating groove of the second heater 12 get a main drawing, wherein the inner consolidation structure of the polymer filaments with the obvious glass transition temperature is further loosened, so that each filament of the multi-filaments is completely in the high-elastic state, as a result, each filaments become further attenuated and get inner molecular orientation and crystallization further improvements, increasing the strength of the filaments and quickly achieving uniform and consistent high-yield output of the nano-filaments, so as to avoid the conventional nano-spinning route such as electro-spinning and centrifugal spinning. As a result, a problem that insufficient drafting of filaments during the conventional nano-spinning incurs poor orientation of the macromolecules in the nano-fibers, unsatisfactory fineness of the nano-fibers, low strength of the nano-fibers, poor adhesion and durability of the nano-fibers. Therefore, nano-fibers overlaying onto the fabric surface are very easy to be worn off, and nano-fiber strands fail to be spun into a yarn by conventional ring spinning is solved; after the main drawing, the multi-filaments outputting from the front roller nip are converged and twisted to form a yarn, subsequently the yarn passes through a pig-tail guider 15 of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin; wherein various kinds of films can be fiberized, attenuated and twisted in one step for forming the yarn, effectively integrating the film industry and the textile and garment industry as functional films can be directly used to produce textile yarns of fibers in a high-speed and high-efficient way; Therefore this invention takes in films as the expanded textile raw materials, and breaks restrictions of conventional nano-spinning producing nano-fibers in low bulk and low-speed unable to meet the textile industrial application requirements, which provides an effective method for functional films to be used in the production and processing of yarn and apparel fabrics.

(7) Referring to the method to form yarn via film fiberizing spinning with different kinds of the films, embodiments of the present invention are further illustrated.

Embodiment 1

(8) The method to form yarn via film fiberizing spinning with polyethylene terephthalate (PET) films.

(9) A width of the PET films is 10 mm, and a thickness is 0.1 mm; the cut resistance apron 3 is made of the super high-strength rubber; the distance between cutter edges of adjacent loop blades is 0.1 mm; the first heater 9 and the second heater 12 are externally connected to a 36 v safety power supply, so as to heat the heating groove of the first heater 9 to 100 C. and the heating groove of the second heater 12 to 120 C. The method comprises steps of placing a film roll 1 of the PET films between the bearing roller 16 and the unwinding roller 4, wherein films unwound from the film roll 1 enter the cutting zone formed between the cut resistance apron 3 and the unwinding roller 4; cutting and fiberizing the films to form belt-like multi-filaments which are evenly paved before entering the first drafting zone; primary drawing the multi-filaments in the first drafting zone with a first drafting rate of 1.05 before entering the second drafting zone by the rear roller nip through the guiding tunnel of the filament guider 6; heating the multi-filament in the heating groove in the second drafting zone at 100 C., wherein inner macromolecules of each filaments are in a high-elastic state as the inner consolidation structure of the PET filaments is loosened; secondary drawing the multi-filament in the high-elastic state in the second drafting zone with a drafting rate of 4; then entering the third drafting zone by the middle roller nip; heating the multi-filaments in the heating groove in the third drafting zone at 120 C., wherein the inner macromolecules of the filaments are in the high-elastic state as the inner consolidation structure of the PET filaments is further loosened, so as to fully drawing with main drafting rate; main drawing the multifilament in the third drafting zone with a drafting rate of 30; then entering a twisting zone by the front roller nip; gathering and twisting the drafted multi-filaments to form a yarn, passing the yarn through a pig-tail guider 15 of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin.

(10) Twist degree of the yarn formed is 115 twists/m, and five polyester filaments are randomly removed from an inner of the yarn by untwisting, then the five polyester filaments are observed by a scanning electron microscopy; the observed results show that finenesses of the five polyester filaments are in a range of 806-862 nm, indicating that the produced yarn is constituted by ultra-fine polyester filament fibers.

Embodiment 2

(11) The method to form yarn via film fiberizing spinning with polyamide (nylon) films.

(12) A width of the polyamide films is 20 mm, and a thickness is 0.1 mm; the cut resistance apron 3 is made of the ultra-high-strength polyethylene; a distance between cutter edges of adjacent loop blades is 2.5 mm; the first heater 9 and the second heater 12 are externally connected to a 24 v safety power supply, so as to heat the heating groove of the first heater 9 to 120 C. and the heating groove of the second heater 12 to 150 C. The method comprises steps of placing a film roll 1 of the polyamide films between the bearing roller 16 and the unwinding roller 4, wherein films unwound from the film roll 1 enter the cutting zone formed between the cut resistance apron 3 and the unwinding roller 4; cutting the films for forming belt-like multifilament which are evenly paved before outputting to the first drafting area, primary drawing the multi-filaments in the first drafting zone with a drafting rate of 1.03 before entering the second drafting zone by the rear roller nip through the guiding tunnel of the filament guider 6; heating the multifilament in the heating groove in the second drafting zone at 100 C., wherein inner macromolecules of filaments are in a high-elastic state as the inner consolidation structure of the polyamide filaments is loosened; secondary drawing the multifilament in the high-elastic state in the second drafting zone with a drafting rate of 3; then entering the third drafting zone from the middle roller nip; heating the multi-filaments in the heating groove in the third drafting area at 120 C., wherein the inner macromolecules of the filaments are in the high-elastic state as the inner consolidation structure of the polyamide filaments is further loosened, so as to fully drawing with main drafting rate; main drawing the multi-filaments in the third drafting area with a third drafting rate of 35; then entering a twisting zone from the front roller nip; gathering and twisting the drafted multi-filaments to form a yarn, passing the yarn through a pig-tail guider 15 of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin.

(13) Twist degree of the yarn formed is 65 twists/m, and five polyamide filaments are randomly removed from an inner of the yarn by untwisting, then the five nylon filaments are observed by an optical microscopy; the observed results show that the filaments are thin and long in a branching form, and finenesses of the five polyester filaments are in a range of 800-970 nm, enabling producing yarn containing fine polyamide fibers.

Embodiment 3

(14) The method to form yarn via film fiberizing spinning with polysulfone (PSF) films.

(15) PSF films are nanofiber films whose nanofibers have a fineness range from 400 nm to 600 nm, belonging to thermoplasticity nanofiber unwoven films; a width of the PSF films is 22 mm, and a thickness is 0.1 mm; the cut resistance apron 3 is made of the aramid; a distance between cutter edges of adjacent loop blades is 3 mm; the first heater 9 and the second heater 12 are externally connected to a 36 v safety power supply, so as to heat the heating groove of the first heater 9 to 200 C. and the heating groove of the second heater 12 to 240 C. The method comprises steps of placing a film roll 1 of the PSF films between the bearing roller 16 and the unwinding roller 4, wherein films unwound from the film roll 1 enter the cutting zone formed between the cut resistance apron 3 and the unwinding roller 4; cutting and fiberizing the films to form belt-like multi-filaments which are evenly paved before entering the first drafting zone; primary drawing the multi-filaments in the first drafting zone with a drafting rate of 1.05 before entering the second drafting zone from the rear roller nip through the guiding tunnel of the filament guider 6; heating the multifilament in the heating groove in the second drafting zone at 200 C., wherein inner macromolecules of the nanofibers of filaments are in a high-elastic state as the inner consolidation structure of the nanofibers of the PSF filaments is loosened; secondary drawing the multi-filaments in the high-elastic state in the second drafting zone with a drafting rate of 2; then entering the third drafting zone from the middle roller nip; heating the multifilament in the heating groove in the third drafting zone at 140 C., wherein the inner macromolecules of nanofibers of the filaments are in the high-elastic state; main drawing the multi-filaments in the third drafting zone with a drafting rate of 3; then entering a twisting zone from the front roller nip; gathering and twisting the drafted multi-filaments to form a yarn, passing the yarn through a pig-tail guider 15 of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin.

(16) Twist degree of the yarn formed is 85 twists/m, and one PFS filament is randomly removed from an inner of the yarn by untwisting, then the five PFS filaments are observed by a scanning electron microscopy; the observed results show that the PFS filament is mesh-like, continuous and thin with a width of 1.0 mm and a thickness of 0.04 mm; the PFS filament comprises the nanofibers, and finenesses of the nanofibers are in a range of 97-178 nm, enabling producing yarn containing PSF nanofibers.

Embodiment 4

(17) The method to form yarn via film fiberizing spinning with inorganic copper films.

(18) A width of the inorganic copper films is 12 mm, and a thickness is 0.06 mm; the cut resistance apron 3 is made of the super high-strength rubber; a distance between cutter edges of adjacent loop blades is 3 mm; the first heater 9 and the second heater 12 are externally connected to a 36 v safety power supply, so as to heat the heating groove of the first heater 9 to 60 C. and the heating groove of the second heater 12 to 60 C. The method comprises steps of placing a film roll 1 of the inorganic copper films between the bearing roller 16 and the unwinding roller 4, wherein films unwound from the film roll 1 enter the cutting zone formed between the cut resistance apron 3 and the unwinding roller 4; cutting and fiberizing the films to form belt-like multi-filaments which are evenly paved before entering the first drafting zone; primary drawing the multi-filaments in the first drafting zone with a drafting rate of 1.05 before entering the second drafting zone from the rear roller nip through the guiding tunnel of the filament guider 6; heating the multifilament in the heating groove in the second drafting zone at 60 C., wherein an inner structure of a copper material cannot be loosened, but it is conducive to stretching and extending copper filaments of the belt-like multi-filaments; secondary drawing the multifilament in the second drafting zone with a drafting rate of 1.05; then entering the third drafting zone from the middle roller nip; heating the multifilament in the heating groove in the third drafting zone at 60 C., in such a manner that the filaments are easy to be drafted and extended; main drawing the multi-filaments in the third drafting zone with a drafting rate of 1.05; then entering a twisting zone from the front roller nip; gathering and twisting the drafted multi-filaments to form a yarn, passing the yarn through a pig-tail guider 15 of yarn, a ring and a traveler successively, and is finally winding onto a yarn bobbin. Twist degree of the yarn formed is 60 twists/m, and one copper filament is randomly removed from the inner of the yarn by untwisting, then the copper filament is observed by an optical microscopy; the observed results show that the coper filament is continuous and thin with a width of 0.75 mm and a thickness of 0.05 mm, enabling production of copper fiber yarn.

(19) One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

(20) It will thus be seen that the objects of the present invention have been fully and effectively accomplished. Its embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.