Device and method for producing a multicolor yarn

Abstract

A draw device into which at least two filaments are guided for producing a multi-coloured yarn from differently coloured filaments which consist of a plurality of endless filaments includes a pair of intake rollers for receiving the at least two filaments. Two pairs of drafting system rollers follow the intake rollers to draw the at least two filaments. A texturizing device comprising a texturizing nozzle with a cooling drum is disposed downstream of the two pairs of drafting system rollers to texturize the at least two filaments, wherein at least one yarn is formed from the filaments in the texturizing nozzle. At least one further nozzle is disposed exclusively upstream of the texturizing device in which each filament is separately interlaced. The filaments are drawn on at least one of the two pairs of drafting system rollers at a speed of at least 1,700 m/min.

Claims

1. A draw device into which at least two individual filaments are guided for producing a multi-coloured yarn from differently coloured filaments, which consist of a plurality of endless filaments, comprising: a pair of intake rollers for receiving the at least two individual filaments; two pairs of drafting system rollers following the pair of intake rollers to draw the at least two individual filaments; a texturizing device comprising a texturizing nozzle with a cooling drum disposed downstream of the two pairs of drafting system rollers for receiving the at least two individual filaments to form at least one texturized yarn in the texturizing nozzle; and at least one further nozzle to separately interlace each of the at least two individual filaments disposed downstream the two pairs of drafting system rollers and upstream of the texturizing device; wherein the at least two individual filaments are drawn on at least one of the two pairs of drafting system rollers at a speed of at least 1,700 m/min.

2. The draw device according to claim 1 wherein the at least one further nozzle includes an additional nozzle disposed downstream the pair of intake rollers and upstream of the two pairs of drafting system rollers.

3. The draw device according to claim 1, wherein a gaseous medium at a pressure of 0.01 to 12 bars is blown into the at least one further nozzle.

4. The draw device according to claim 1, wherein one of the pairs of drafting system rollers is configured as duo rollers.

5. The draw device according to claim 1, further including a guide which guides each of the at least two individual filaments separately from each other, disposed upstream of the two pairs of drafting system rollers.

6. The draw device according claim 1, further including at least one further pair of drafting system rollers disposed downstream of the texturizing device with the cooling drum which cool-off the at least one yarn.

7. The draw device according to claim 6, wherein the at least one further pair of drafting system rollers cools the at least one yarn to a temperature of 0° C. to 80° C.

8. The device according to claim 1, wherein the at least two endless individual filaments are drawn on the pair of the two pairs of drafting system rollers which is directly disposed upstream of the texturizing nozzle at the speed of at least 1,700 m/min.

9. A method for producing a multi-coloured yarn from differently coloured filaments, which consist of at least two endless individual filaments, comprising: guiding the at least two endless individual filaments into a draw device by a pair of intake rollers drawing the at least two endless individual filaments by at least two pairs of drafting system rollers following the pair of intake rollers, including drawing the at least two endless individual filaments on at least one of the at least two pairs of drafting system rollers at a speed of at least 1700 m/min; subsequently texturizing the at least two endless individual filaments with a texturizing device comprising a texturizing nozzle to produce a texturized yarn and cooling the texturized yarn a cooling drum; and prior to the texturizing, and after the drawing the at least two endless individual filaments by the at least two pairs of drafting system rollers, respectively separately interlacing each of the at east two endless individual filaments with at least one further nozzle.

10. The method according to claim 9, further including additionally interlacing the at least two endless individual filaments prior to the drawing.

11. The method according to claim 9, including realizing the interlacing the of at least two endless individual filaments by a gaseous medium at a pressure of 0.01 to 12 bars.

12. The method according to claim 9, including, after the texturizing, cooling the yarn by at least one pair of drafting system rollers.

13. The method according to claim 12, wherein the cooling the yarn by at least one pair of drafting system rollers cools the yarn to a temperature of 0° C. to 80° C.

14. The method of claim 9, wherein the drawing the at least two endless individual filaments by the at least two pairs of drafting system rollers includes drawing the at least two endless individual filaments on the pair of the at least two pairs of drafting system rollers which is directly disposed upstream of the texturizing nozzle at the speed of at least 1,700 m/min.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further measures enhancing the invention will be illustrated in more detail in the following in conjunction with the description of one preferred exemplary embodiment of the invention based on the Figures. It shows:

(2) FIG. 1: a partial illustration of a first exemplary embodiment of a spin-draw installation;

(3) FIG. 2: a partial illustration of a second exemplary embodiment of a spin-draw installation;

(4) FIG. 3: a partial illustration of a third exemplary embodiment of a spin-draw installation.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1 shows a section of a spin-draw installation according to a first exemplary embodiment, in which six differently coloured filaments F1 to F6, for example made from polyamide 6 (PA6), enter the draw device 1 from non-illustrated spinning nozzles. Basically, said type of installation allows for processing of up to twelve filaments, wherein said exemplary embodiment describes the processing of six filaments. The colouration of the filaments F1 to F6 is realized via different batches of plastic materials, which are separately extruded and respectively transformed to an endless filament by means of a spinning head. Each filament F1 to F6 consists respectively of up to 1000 endless filaments, which are combined to respectively one filament F1 to F6 downstream the spinning head upstream the draw device 1. The filaments F1 to F6 enter the draw device 1 with a speed of 925 m/min, and, in a preparation device 2, they are treated with oil or a sliding agent, and are rerouted to a first pair of drafting system rollers 5.1, 5.2 via a pair of intake rollers 3.1, 3.2.

(6) Optionally, a first nozzle 4, in which the six filaments F1 to F6 are laterally charged with a gaseous medium, preferably air, at a pressure of 0.01 to 12 bar, may be disposed between the pair of intake rollers 3.1, 3.2 and the pair of drafting rollers 5.1, 5.2. The nozzle 4 includes a separate guide for each filament F1 to F6 so that the filaments F1 to F6 do not get in contact with each other. Up to 1000 endless filaments are interlaced with each other within the guide of the nozzle 4 so that six separately interlaced filaments F1 to F6 exit from the nozzle 4, and are guided onto the pair of drafting system rollers 5.1, 5.2.

(7) At a speed of 925 m/min, the filaments F1 to F6 are heated to a temperature of 65° C. at the pair of drafting system rollers 5.1, 5.2. Said pair of drafting system rollers 5.1, 5.2 is configured as a mono roller, in which just the drafting system roller 5.1 is driven. The drafting system roller 5.2 is not driven, but rotates along due to the tension of the filaments F1 to F6. Also, the drafting system rollers 5.1, 5.2 may be configured as duo rollers, in which both rollers are driven, and which essentially have a same sized exterior diameter. This is advantageous in that the gradual heating of the filaments F1 to F6 may be realized more continuously over a longer period of time, which is advantageous for transforming the molecule chains. In this case, the surfaces of the pairs of drafting system rollers may be heated by means of a non-illustrated heating system, for example an electrical, vapour-based or liquid-based heating system, wherein in the following, it is assumed that during the at least double circulation around the pairs of draw rollers, the filaments F1 to F6 have also taken on the temperature of the pairs of draw rollers.

(8) The filaments F1 to F6 are guided from the pair of rollers 5.1, 5.2 to the pair drafting rollers 6.1, 6.2, wherein previously they are kept at a distance from each other by means of a guide 14. The further drawing and heating on the pair of drafting rollers 6.1, 6.2, which are configured as duo, is realized at a speed of 2,500 m/min and a heating to 170° C.

(9) The nozzle 7 likewise includes a separate guide for each filament F1 to F6 so that the filaments F1 to F6 do not get in contact with each other. The up to 1000 endless filaments are interlaced with each other within the guide of the nozzle 7 so that six separately interlaced filaments F1 to F6 exit from the nozzle 7 and enter the texturizing nozzle. Within the nozzle 7, the six filaments F1 to F6 are interlaced by means of a blown-in gaseous medium, preferably air, at a pressure of 0.01 to 12 bars. The formation of the yarns G1, G2 is realized in the texturizing nozzle 8, wherein altogether two crimped yarns G1, G2 are created in the texturizing nozzle 8, which respectively consist of three filaments F1 to F3 and F4 to F6 having respectively one colour per filament. Thereby, each yarn G1, G2 may include three filaments having three different colours, which are clearly distinguished from each other. However, depending on the configuration of the installation, each yarn G1, G2 may consist of two or four filaments having a different colour.

(10) The advantage of the invention in this embodiment consists in the fact that the yarn G1, G2 having the three filaments clearly indicates the colours of the filaments without causing any blending. According to the state-of-the-art this would not be possible, because the individual filaments F1 to F3 and F4 to F6 would bond to each other, which would result in an indistinct dissociation of the colours. In contrast to the state-of-the-art, surprisingly it has proven that with an extremely short detention time within the nozzle 7, the subsequent bonding of the filaments F1 to F3 and F4 to F6 may be prevented in the texturizing nozzle. As the speed of the filaments F1 to F6 in the entire draw device 1 is the highest with the drafting system rollers 6.1, 6.2, simultaneously, the detention time of the filaments F1 to F6 is the shortest in the downstream disposed nozzle 7. With a speed of the filaments F1 to F6 around the drafting system rollers 6.1, 6.2 of 2,500 m/min for PA6, the detention time of the filaments F1 to F6 in the nozzle 7 amounts to just about 5 milliseconds.

(11) The parameters for the drafting system rollers 6.1, 6.2 may be the following with other plastic materials:

(12) TABLE-US-00001 Parameter for Unit PP PA6 PET PA6-6 drafting system speed m/min 2030 2500 3200 2960 rollers 6.1, 6.2 temperature ° C. 130 170 165 200

(13) Advantageously, now just two yarns G1, G2 are texturized and further drawn, which makes the installation more compact and less expensive, than if six, respectively up to twelve filaments would be processed. The downstream drafting system rollers may be configured to be shorter, which simplifies the temperature control and the bearings.

(14) After the nozzle 7, the filaments F1 to F6 enter the downstream disposed texturizing nozzle 8, in which they converge to the yarn G1 and G2, whereby the texturizing nozzle 8 just needs to be provided with two nozzle channels. Here, two crimped yarns G1, G2 are produced at a temperature of 180° C., the texture thereof being frozen on the downstream cooling drum 9. Then, after the nozzle 7, the filaments F1 to F6 are heated again in the texturizing nozzle 8, for PA6 from 170° C. to 180° C.

(15) A subsequent light drawing is realized with cold drafting system rollers 10.1, 10.2 and 11.1, 11.2. On the drafting system roller 10.1, the speed of the yarn amounts to 2,222 m/min. The drafting system roller 11.1 transports the yarn G1, G2 with a speed of 2.257 m/min at a temperature of 20° C. to 80° C., for example. Preferably, the drafting system rollers 10.1, 10.2, 11.1, 11.2 may be cooled.

(16) During a final deflection by means of the deflector 12 towards the lapper 13, the yarn G1, G2 is wound onto two coils at a speed of 2201 m/min.

(17) This installation is advantageous in that an existing installation with six, respectively with up to twelve entering filaments just needs one texturizing nozzle 8 with two, respectively with up to four channels, such that subsequently the drawing with the drafting system rollers 10.1, 10.2, 11.1, 11.2 may be build shorter.

(18) In comparison to the exemplary embodiment of FIG. 3, the nozzle 4 may be optionally employed. The method for separately interlacing the filaments F1 to F6 in the nozzle 7 and combining them to yarns G1, G2 in the texturizing nozzle 8 may be also employed without the nozzle 4 (FIG. 3), and achieves good results. The utilization of the nozzle 4 for interlacing the individual filaments F1 to F6 is advantageous in that the texture of each individual filament F1 to F6 is more stable, which positively influences on the following interlacing in the nozzle 7. With the nozzle 4, which effects an interlacing of the up to 1000 endless filaments of each filament F1 to F6, the colour separation becomes even clearer after interlacing in the nozzle 7.

(19) In a second exemplary embodiment according to FIG. 2, for example the six filaments F1 to F6 are separately interlaced by utilizing the nozzle 4 between the pair of intake rollers 3.1, 3.2 and the drafting system rollers 5.1, 5.2. Based on the short detention time of the filaments F1 to F6 in the nozzle 4, a separate interlacing may be realized such that also in the yarns G1, G2, which are subsequently produced from the six filaments F1 to F6 in the texturizing nozzle 8, a clear colour separation is achieved. The further processing of the filaments F1 to F6 is realized according to the exemplary embodiment 1, however, without the nozzle 7. This configuration is advantageous in that the separately interlaced filaments F1 to F6 may be guided from the nozzle 4 on in an easier and more stable manner through the entire installation. Also according to this exemplary embodiment, due to a very short detention time of the filaments F1 to F6 in the nozzle 4, the colour separation may be maintained. In this case, the detention time of the plastic material of the filaments F1 to F6 in the nozzle 7 amounts to about 10 milliseconds.

(20) In the exemplary embodiment of FIG. 3, the filaments (F1 to F6) are exclusively interlaced with the nozzle 7 upstream the texturizing nozzle 8, and respectively three filaments F1 to F3 and F4 to F6 are connected to each other to one yarn G1, G2 in the texturizing nozzle 8. Otherwise, the exemplary embodiment is identical to the exemplary embodiment of FIG. 1.

(21) According to FIG. 3, six differently coloured filaments F1 to F6, for example made from polyamide 6 (PA6), enter the draw device 1 from non-illustrated spinning nozzles. The colouration of the filaments F1 to F6 is realized by different batches of plastic materials, which are separately extruded and respectively transformed into an endless filament by means of a spinning head. Each filament F1 to F6 consists respectively of up to 1000 endless filaments, which are united to respectively one filament F1 to F6 downstream the spinning head upstream the draw device 1. The filaments F1 to F6 enter the draw device 1 with a speed of 925 m/min, and, in a preparation device 2, they are treated with oil or a sliding agent, and are rerouted to a first pair of drafting system rollers 5.1, 5.2 via a pair of intake rollers 3.1, 3.2. At a speed of 925 m/min, the filaments F1 to F6 are heated to a temperature of 65° C. at the pair of drafting system rollers 5.1, 5.2. Said pair of drafting system rollers 5.1, 5.2 is configured as a mono roller, in which just the drafting system roller 5.1 is driven. The filaments F1 to F6 are guided from the pair of drafting rollers 5.1, 5.2 to the pair of drafting rollers 6.1, 6.2, wherein previously they are kept at a distance from each other by means of a guide 14. The further drawing and heating on the pair of drafting rollers 6.1, 6.2, which are configured as duo, is realized at a speed of 2,500 m/min and a heating to 170° C.

(22) The nozzle 7 likewise includes a separate guide for each filament F1 to F6 so that the filaments F1 to F6 do not get in contact with each other. The up to 1000 endless filaments are interlaced with each other within the guide of the nozzle 7 so that six separately interlaced filaments F1 to F6 exit from the nozzle 7 and enter the texturizing nozzle. Within the nozzle 7, the six filaments F1 to F6 are interlaced with each other by means of a blown-in gaseous medium, preferably air, at a pressure of 0.01 to 12 bars. The formation of the yarns G1, G2 is realized in the texturizing nozzle 8, wherein altogether two crimped yarns G1, G2 are created in the texturizing nozzle 8, which respectively consist of three filaments F1 to F3 and F4 to F6 having respectively one colour per filament. Thereby, each yarn G1, G2 may include three filaments having three different colours, which are clearly distinguished from each other. However, depending on the configuration of the installation, each yarn G1, G2 may consist of two or four filaments varying in colour.

(23) The advantage of the invention in this embodiment consists in the fact that the yarn G1, G2 having the three filaments clearly indicates the colours of the filaments without any blending occurring. According to the state-of-the-art this would not be possible, because the individual filaments F1 to F3 and F4 to F6 would bond to each other, which would result in a non-distinct dissociation of the colours. In contrast to the state-of-the-art, surprisingly, it has proven that with an extremely short detention time within the nozzle 7, the subsequent bonding of the filaments F1 to F3 and F4 to F6 may be prevented. As the speed of the filaments F1 to F6 in the entire draw device 1 is the highest with the drafting system rollers 6.1, 6.2, simultaneously, the detention time of the filaments F1 to F6 is shortest in the downstream disposed nozzle 7. With a speed of the filaments F1 to F6 around the drafting system rollers 6.1, 6.2 of 2,500 m/min for PA6, the detention time of the filaments F1 to F6 in the nozzle 7 amounts to just about 5 milliseconds.

(24) The parameters for the drafting system rollers 6.1, 6.2 may be the following with other plastic materials:

(25) TABLE-US-00002 Parameter for Unit PP PA6 PET PA6-6 drafting system speed m/min 2030 2500 3200 2960 rollers 6.1, 6.2 temperature ° C. 130 170 165 200

(26) Advantageously, now just two yarns G1, G2 are texturized and further drawn, which makes the installation more compact and less expensive, than if six, respectively up to twelve filaments would be processed. The downstream drafting system rollers may be configured to be shorter, which simplifies the temperature control and the bearings.

(27) After the nozzle 7, the filaments F1 to F6 enter the downstream disposed texturizing nozzle 8, in which they converge to the crimped yarn G1 and G2, whereby the texturizing nozzle 8 just needs to be provided with two nozzle channels. Here, at a temperature of 180° C. are produced from the filaments two crimped yarns G1, G2, the texture thereof being frozen on the downstream cooling drum 9. Then, after the nozzle 7, the filaments F1 to F6 are heated again in the texturizing nozzle 8, for PA6 from 170° C. to 180° C.

(28) A following light drawing is realized with cold drafting system rollers 10.1, 10.2 and 11.1, 11.2. On the drafting system roller 10.1, the speed of the yarn amounts to 2,222 m/min. The drafting system roller 11.1 transports the yarn G1, G2 with a speed of 2.257 m/min at a temperature of 20° C. to 80° C. Preferably, the drafting system rollers 10.1, 10.2, 11.1, 11.2 are cooled.

(29) During a final deflection by means of the deflector 12 towards the lapper 13, the yarn G1, G2 is wound onto two coils at a speed of 2201 m/min.

(30) This installation is advantageous in that an existing installation with six, respectively with up to twelve entering filaments just needs one texturizing nozzle 8 with two, respectively with up to four channels, such that subsequently the drawing with the drafting system rollers 10.1, 10.2, 11.1, 11.2 may be build to be shorter.

(31) Altogether up to 12 filaments (F1 to F12) of different colours having respectively up to 1000 endless filaments may be processed in the installation, such as to be able produce up to four yarns (G1 . . . G4), wherein each yarn may consist of two, three or four filaments varying in colour.

(32) The invention may be employed with all types of polymers, such as for example PP, PET, PA6, PA6.6 or PBT.

(33) The invention in the embodiment thereof is not limited to the above-indicated preferred exemplary embodiment. Rather, a number of variants is conceivable, which utilize the illustrated solution, even though basically the embodiments may be different. All the features and/or advantages including constructional particularities or spatial arrangements resulting from the claims, the description or the drawings, may be essential to the invention individually or in the most various combinations.

REFERENCE NUMERALS

(34) 1 draw device 2 preparation device 3.1, 3.2 intake rollers 4 nozzle 5.1, 5.2 drafting system rollers 6.1, 6.2 drafting system rollers 7 nozzle 8 texturizing device 9 cooling drum 10.1, 10.2 drafting system rollers 11.1, 11.2 drafting system rollers 12 deflection 13 lapper 14 guide F1 . . . Fn filaments G1 . . . Gn yarn