APPARATUS AND METHOD FOR PRODUCING A CRIMPED COMPOSITE THREAD

Abstract

Techniques produce a crimped composite thread, in which multiple individual threads are extruded in each case in the form of a plurality of strand-shaped filaments, cooled, drawn by means of a drawing device and together crimped by means of a crimping device to form the composite thread. Before the multifilament individual threads are crimped, they are entangled separately in each case by means of an entangling unit of an entangling device. A position and/or orientation of at least one of the entangling units relative to the drawing device, the crimping device and/or a further one of the entangling units is changed during the production of the crimped composite thread.

Claims

1. Apparatus for producing a crimped composite thread, having a spinning device, a cooling device and a drawing device for producing multiple multifilament individual threads, having a crimping device for bringing the individual threads together to form the composite thread and having an entangling device, arranged upstream of the crimping device, for entangling the individual threads separately in each case by means of entangling units, wherein a position and/or orientation of at least one of the entangling units relative to the drawing device, the crimping device and/or a further one of the entangling units can be changed by means of at least one actuator.

2. Apparatus according to claim 1, wherein each entangling unit has an entangling nozzle, which entangling nozzles are arranged on a common carrier of the entangling device, and the position and/or orientation of the carrier can be changed by means of the at least one actuator.

3. Apparatus according to claim 2, wherein each entangling unit has an individual carrier for holding the associated entangling nozzle, wherein the position and/or orientation of each individual carrier can be changed in each case by means of at least one actuator.

4. Apparatus according to claim 3, wherein an adjustment range of at least one of the actuators is from 5 mm to 60 mm, preferably from 5 mm to 25 mm.

5. Apparatus according to claim 3, wherein the at least one actuator is configured to permit a movement of the carrier and/or individual carrier coupled with said actuator in at least one of six degrees of freedom, in particular a displacement in an X, Y and/or Z direction and/or a rotation about an X, Y and/or Z axis.

6. Apparatus according to claim 3, wherein the at least one actuator is connected to a control device for the activation, preferably the automatic activation, of said actuator.

7. Apparatus according to claim 1, wherein a separately controllable compressed air supply is associated with each of the entangling units.

8. Method for producing a crimped composite thread, in which multiple individual threads are extruded in each case in the form of a plurality of strand-shaped filaments, cooled, drawn by means of a drawing device and together crimped by means of a crimping device to form the composite thread, wherein, before the multifilament individual threads are crimped, they are entangled separately in each case by means of entangling units of an entangling device, wherein a position and/or orientation of at least one of the entangling units relative to the drawing device, the crimping device and/or a further one of the entangling units is changed during the production of the crimped composite thread.

9. Method according to claim 8, wherein the position and/or orientation of the entangling device, having all the entangling units together, relative to the drawing device and/or relative to the crimping device is changed during the production of the crimped composite thread.

10. Method according to claim 8, wherein the position and/or orientation of at least one of the entangling units is changed automatically by means of a control device on the basis of measured properties of the composite thread, which includes colour thereof, in order to achieve desired properties of the composite thread, which includes colour thereof.

11. Method according to claim 8, wherein the position and/or orientation of at least one of the entangling units is changed by means of the control device on the basis of a predefined movement pattern present in the control device.

12. Method according to one claim 8, wherein the individual threads are entangled with in each case different compressed air set-point values of a compressed air supply.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0035] In the following text, preferred embodiments will be described in greater detail with reference to the accompanying figures.

[0036] FIG. 1 shows, schematically, a first embodiment of the apparatus for producing a crimped composite thread in a side view.

[0037] FIG. 2 shows, schematically, an entangling device of a second embodiment of the apparatus for producing a crimped composite thread in a plan view.

[0038] FIG. 3 shows, schematically, an entangling device of a third embodiment of the apparatus for producing a crimped composite thread in a plan view.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0039] The apparatus for producing a crimped composite thread 1 according to FIGS. 1 to 3 has, inter alia, a spinning device 2, a cooling device 3 and a drawing device 4 for producing multiple multifilament individual threads 5.1, 5.2, 5.3. The apparatus for producing the crimped composite thread 1 further has, inter alia, a crimping device 6 for bringing the individual threads 5.1, 5.2, 5.3 together to form the composite thread 1, and an entangling device 7, arranged upstream of the crimping device 6, for separately entangling the individual threads 5.1, 5.2, 5.3 by means of in each case an entangling unit 7.1, 7.2, 7.3.

[0040] According to FIG. 1, the crimping device 6 is formed by a stuffer box crimping device, which has a conveying nozzle 6.1, a stuffer box 6.2 and a cooling drum 6.3. The individual threads 5.1, 5.2 and 5.3 are together compressed by a hot conveying medium to form a fibre plug. The fibre plug is then cooled on the periphery of the cooling drum 6.3 and opened to form the composite thread 1.

[0041] A position and/or orientation of at least one of the entangling units 7.1, 7.2, 7.3 relative to the drawing device 4, the crimping device 6 and/or a further one of the entangling units 7.1, 7.2, 7.3 can be changed by means of at least one actuator.

[0042] The double arrows shown adjacent to the entangling device 7 in FIGS. 1 and 2 and also adjacent to the entangling units 7.1, 7.2, 7.3 in FIGS. 2 and 3 symbolize the possible movements which can be implemented by means of such actuators, wherein the actuators themselves are not shown for reasons of clarity. The double arrows are shown with reference to cartesian coordinate systems with X, Y and Z axes. FIG. 1 shows the double arrows in the associated cartesian coordinate system on the one hand next to the entangling device 7 and additionally in an enlarged representation for the purpose of clarification.

[0043] Each entangling unit 7.1, 7.2, 7.3 has an entangling nozzle 7.1.d, 7.2.d, 7.3.d, which entangling nozzles are arranged according to FIGS. 1 and 2 on a common carrier 8 of the entangling device 7. The position and/or orientation of the carrier 8 can be changed by means of the at least one actuator.

[0044] The first and second embodiments of the apparatus for producing a crimped composite thread 1 according to FIGS. 1 and 2 have such a common carrier 8. The third embodiment of the apparatus for producing a crimped composite thread 1 is without a common carrier 8. The carrier 8 is mounted preferably on a machine frame (not shown here) by means of a bearing device (not shown here) so as to be movable relative to the surroundings. Such a bearing device could also be formed by means of the actuator. The actuator is preferably also held on such a machine frame. The drawing device 4 and the crimping device 6 are also in particular connected to the machine frame.

[0045] According to FIGS. 2 and 3, each entangling unit 7.1, 7.2, 7.3 has an individual carrier 8.1, 8.2, 8.3 for holding the associated entangling nozzle 7.1.d, 7.2.d, 7.3.d. The position and/or orientation of each individual carrier 8.1, 8.2, 8.3 can be changed in each case by means of at least one actuator.

[0046] The first embodiment of the apparatus for producing a crimped composite thread 1 from FIG. 1 is without such individual carriers. According to FIG. 2, the individual carriers 8.1, 8.2, 8.3 are arranged on the common carrier 8 and are then each also movable relative to the carrier 8 by means of the associated actuator. Each individual carrier 8.1, 8.2, 8.3 thus has a bearing device (not shown here) by means of which each individual carrier 8.1, 8.2, 8.3 is coupled with the carrier 8, wherein these bearing devices can also be formed by means of the respective actuators. According to FIG. 3, the individual carriers 8.1, 8.2, 8.3 are mounted preferably on a machine frame (not shown here) by means of a respective bearing device (not shown here) so as to be movable relative to the surroundings without an intermediate common carrier. Such bearing devices could also be formed by means of the actuators. The actuators are preferably also held on such a machine frame.

[0047] An adjustment range of at least one of the actuators is from 5 mm to 60 mm, preferably from 5 mm to 25 mm.

[0048] In particular, the actuator has a central rest position, from which the actuator is movable in two opposite directions in each case by from 10 mm to 30 mm, preferably from 17.5 mm to 22.5 mm.

[0049] The at least one actuator is configured to permit a movement of the carrier 8 and/or individual carrier 8.1, 8.2, 8.3 coupled with the actuator in at least one of six degrees of freedom, in particular a displacement in an X, Y and/or Z direction and/or a rotation about an X, Y and/or Z axis.

[0050] The displacements in the X, Y and/or Z direction are symbolized in FIGS. 1 to 3 in each case by a straight double arrow, and the rotation about the X, Y and/or Z axis is symbolized in each case by a curved double arrow. For displacement in one of the directions, an electric, pneumatic or hydraulic linear actuator is preferably provided. In order to permit a displacement of the carrier 8 in all three directions, three such linear actuators, for example, in each case arranged at right angles to one another, are then provided. In order to produce rotations, electrically, pneumatically or hydraulically operable rotary motors could be provided. It would further be conceivable also to make a rotation possible by means of linear actuators, which then engage eccentrically to a rotary bearing of the respective carrier 8 or individual carrier 8.1, 8.2, 8.3 on the associated carrier 8 or individual carrier 8.1, 8.2, 8.3. It is possible to combine different actuators with one another in any desired manner, for example at least one of the carriers 8 and/or individual carriers 8.1, 8.2, 8.3 could be movable by means of a robotic arm having a plurality of actuators.

[0051] The at least one actuator is connected to a control device for the activation, preferably the automatic activation, of the actuator.

[0052] Each of the entangling units 7.1, 7.2, 7.3 has an associated separately controllable compressed air supply 7.1.z, 7.2.z, 7.3.z.

[0053] To that end, the compressed air supplies 7.1.z, 7.2.z, 7.3.z are each connected according to FIGS. 2 and 3 by means of a respective pressure setting means (or device) 9.1, 9.2, 9.3 to a pressure source (not shown here). The flow channels necessary for this purpose are preferably implemented by means of movable hose lines, wherein such movable hose lines allow the entangling units 7.1, 7.2, 7.3 to move or move correspondingly with the entangling units 7.1, 7.2, 7.3. The compressed air supplies 7.1.z, 7.2.z, 7.3.z, in particular the pressure setting means 9.1, 9.2, 9.3 thereof, are connected for the open-loop and/or closed-loop control thereof to the control device.

[0054] In the following text, the components arranged according to FIG. 1 upstream and downstream of the entangling device 7 will now be described again in detail, wherein these components can preferably also be used correspondingly upstream and downstream of the entangling device 7 in the second and third embodiments according to FIGS. 2 and 3. The spinning device 2 is connected to multiple melt generators (not shown here), for example extruders, for providing a polymer melt. The spinning device 2 has a heated spinning beam 10, which carries multiple spinning nozzles 11.1 to 11.3 side by side. The spinning nozzles 11.1 to 11.3 each have on their underside a plurality of nozzle apertures, through each of which a filament bundle of the polymer melt is extruded during operation. Beneath the spinning device 2 there is provided the cooling device 3, by means of which the extruded filaments are cooled. After the filaments have been cooled, they are in each case brought together by the thread guides 12 to form an individual thread 5.1 to 5.3. For pulling out the individual threads 5.1 to 5.3 from the spinning nozzles 11.1 to 11.3 there is provided the drawing device 4, which has a plurality of driven godet wheels. The individual threads 5.1 to 5.3 are individually entangled beforehand by a pre-entangling device 13 by a plurality of pre-entangling nozzles 13.1 to 13.3. On the periphery of the godet wheels of the drawing device 4, the individual threads 5.1 to 5.3 are guided parallel to one another with multiple loops. The drawing device 4 here has two so-called godet wheel duos. After the individual threads 5.1, 5.2 and 5.3 have been pulled out and drawn by the drawing device 4, the individual threads 5.1, 5.2 and 5.3 are separated and entangled by means of the entangling device 7 immediately before being crimped by the crimping device 6. After the crimped composite thread 1 has been cooled, it is removed from the periphery of the cooling drum 6.3 by a take-off godet wheel unit 14, wherein the thread plug is opened. After post-treatment in a post-entangling device 15, the composite thread 1 is wound on a bobbin 17. The composite thread 1 wound on the bobbin 17 can be used directly for producing carpets. For the production of carpets, such composite threads 1 have a predetermined visual appearance, which is defined by the colours of the individual threads 5.1, 5.2 and 5.3.

[0055] These visual appearances of the composite thread are achieved substantially by the entanglement of the individual threads 5.1, 5.2 and 5.3 immediately prior to crimping. The different colours of the individual threads 5.1, 5.2 and 5.3 can be produced, for example, by supplying granules of different colours to the extruders. It is further conceivable to introduce different liquid dyes into the polymer melts between the melt generators, for example the extruders, and the spinning nozzles 11.1, 11.2 and 11.3.

[0056] The method described hereinbelow for producing the crimped composite thread 1 can be carried out in particular by means of the apparatus described hereinbefore for producing the crimped composite thread 1.

[0057] In the method for producing the crimped composite thread 1, multiple individual threads 5.1, 5.2, 5.2 are each extruded as a plurality of strand-shaped filaments, cooled, drawn by means of the drawing device 4 and together crimped by means of the crimping device 6 to form the composite thread 1. Before the multifilament individual threads 5.1, 5.2, 5.3 are crimpled, they are each entangled separately by means of in each case an entangling unit 7.1, 7.2, 7.3 of an entangling device 7.

[0058] A position and/or orientation of at least one of the entangling units 7.1, 7.2, 7.3 relative to the drawing device 4, the crimping device 6 and/or a further one of the entangling units 7.1, 7.2, 7.3 is changed during the production of the crimped composite thread 1.

[0059] The colouring of the composite thread 1 is thus also changed continuously. Desired colour patterns are produced in the composite thread 1, which results in corresponding colour patterns in carpets produced from such composite threads 1.

[0060] The position and/or orientation of the entangling device 7, namely of all the entangling units 7.1, 7.2, 7.3 together, relative to the drawing device 4 and/or relative to the crimping device 6 is changed during the production of the crimped composite thread 1.

[0061] For example, the common carrier 8 is continuously moved to and from in the Z direction between two end positions, so that the distance from the crimping device 6 and the associated feed and discharge angles change continuously. A continuous circular or elliptical movement in a plane would also be conceivable. In the case of such a movement, the common carrier 8 could be moved at a constant speed. In principle, however, all movement sequences which result in a desired colouration of the composite thread 1 and not in undesirable damage to the composite thread are conceivable.

[0062] The position and/or orientation of at least one of the entangling units 7.1, 7.2, 7.3 is, for example, changed automatically by means of a control device on the basis of measured properties of the composite thread 1, in particular the colour thereof, in order to achieve desired properties of the composite thread 1, in particular the colour thereof.

[0063] The aim in the case of such closed-loop control of the colour of the composite thread 1 can be a particular unvarying colour or a particular change in the colour of the composite thread 1.

[0064] The position and/or orientation of at least one of the entangling units 7.1, 7.2, 7.3 is changed by means of the control device, for example, on the basis of a predefined movement pattern present in the control device.

[0065] Movement patterns which have already been tried and tested and the resulting colouration of the composite thread 1 can thus easily be retrieved. Examples of conceivable movement patterns are the changing movement along a line, circular or elliptical movements which have already been mentioned. However, three-dimensional movement patterns are also possible. On the other hand, the movement pattern could also meet particular specifications, such as, for example, a particular, constant discharge angle of one of the individual threads 5.1, 5.2, 5.3 from the entangling device 7.

[0066] The individual threads 5.1, 5.2, 5.3 are, for example, each entangled with different compressed air set-point values of a compressed air supply 7.1.z, 7.2.z, 7.3.z.

[0067] The compressed air set-point values can also be changed during the production of the crimped composite thread 1 if this results in a desired colouration of the composite thread.

LIST OF REFERENCE SIGNS

[0068] 1 composite thread [0069] 2 spinning device [0070] 3 cooling device [0071] 4 drawing device [0072] 5.1 first individual thread [0073] 5.2 second individual thread [0074] 5.3 third individual thread [0075] 6 crimping device [0076] 6.1 conveying nozzle [0077] 6.2 stuffer box [0078] 6.3 cooling drum [0079] 7 entangling device [0080] 7.1 first entangling unit [0081] 7.1.d entangling nozzle of the first entangling unit [0082] 7.1.z compressed air supply of the first entangling unit [0083] 7.2 second entangling unit [0084] 7.2.d entangling nozzle of the second entangling unit [0085] 7.2.z compressed air supply of the second entangling unit [0086] 7.3 third entangling unit [0087] 7.3.d entangling nozzle of the third entangling unit [0088] 7.3.z compressed air supply of the third entangling unit [0089] 8 carrier [0090] 8.1 first individual carrier [0091] 8.2 second individual carrier [0092] 8.3 third individual carrier [0093] 9.1 first pressure setting means [0094] 9.2 second pressure setting means [0095] 9.3 third pressure setting means [0096] 10 spinning beam [0097] 11.1 first spinning nozzle [0098] 11.2 second spinning nozzle [0099] 11.3 third spinning nozzle [0100] 12 thread guide [0101] 13 pre-entangling device [0102] 13.1 first pre-entangling nozzle [0103] 13.2 second pre-entangling nozzle [0104] 13.3 third pre-entangling nozzle [0105] 14 take-off godet wheel unit [0106] 15 post-entangling device [0107] 16 winding apparatus [0108] 17 bobbin