U.S. patent application number 12/922564 was filed with the patent office on 2011-06-09 for multiend package of multifilament polyester bicomponent yarn.
This patent application is currently assigned to INVISTA NORTH AMERICA S.A.R.L.. Invention is credited to Kah Leap Lee, Raymond S.P. Leung, Young D. Nguyen, Paul Wu.
Application Number | 20110133011 12/922564 |
Document ID | / |
Family ID | 41091241 |
Filed Date | 2011-06-09 |
United States Patent
Application |
20110133011 |
Kind Code |
A1 |
Lee; Kah Leap ; et
al. |
June 9, 2011 |
MULTIEND PACKAGE OF MULTIFILAMENT POLYESTER BICOMPONENT YARN
Abstract
Included are multiend packages of multicomponent yarns, where
the yarn is separable into individual ends upon unwinding. The
multicomponent yarn may be a bicomponent yarn, such as a yarn
including compositionally different polyesters in a side-by-side or
eccentric sheath-core configuration. Uses of such multiend packages
are also included.
Inventors: |
Lee; Kah Leap; (n/a, SG)
; Nguyen; Young D.; (Crozet, VA) ; Leung; Raymond
S.P.; (Shatin, HK) ; Wu; Paul; (Chieh-Ting,
TW) |
Assignee: |
INVISTA NORTH AMERICA
S.A.R.L.
WILMINGTON
DE
|
Family ID: |
41091241 |
Appl. No.: |
12/922564 |
Filed: |
March 19, 2009 |
PCT Filed: |
March 19, 2009 |
PCT NO: |
PCT/US09/37589 |
371 Date: |
October 7, 2010 |
Current U.S.
Class: |
242/166 ;
264/103; 57/255 |
Current CPC
Class: |
B65H 54/026 20130101;
D02G 3/36 20130101; D01F 8/14 20130101; B65H 55/005 20130101; D02G
3/362 20130101; B65H 2701/3132 20130101; B65H 51/015 20130101 |
Class at
Publication: |
242/166 ; 57/255;
264/103 |
International
Class: |
D02G 3/04 20060101
D02G003/04; D02H 1/00 20060101 D02H001/00; D02G 1/20 20060101
D02G001/20; B65H 55/00 20060101 B65H055/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 20, 2008 |
US |
61/038267 |
Claims
1. A process for producing a multiend package, the process
comprising: A) melt-spinning two or more compositionally different
polyesters from a single pre-coalescent or post-coalescent
spinneret to form multiple side-by-side or eccentric sheath-core
polyester bicomponent filaments; B) grouping the filaments into at
least two threadlines, each threadline including more than one
filaments; C) taking up the threadlines at speeds greater than
about 300 meters per minute; D) interlacing each threadline; E)
combining the threadlines into a threadline bundle; and F) winding
the threadline bundle onto a tube core at speeds greater than about
300 meters per minute; wherein the threadline bundle is separable
into at least two individual threadlines and the bicomponent
filament comprises poly(trimethylene terephthalate) and at least
one polymer selected from the group consisting of poly(ethylene
terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
2. The process of claim 1, further comprising drawing the
threadlines with a draw ratio greater than about 1.2 and winding
the threadline bundle at speeds greater than about 420 meters per
minute.
3. The process of claim 2, further comprising heat-treating the
threadlines at a temperature between about 100.degree. C. and about
200.degree. C.
4. A process for producing a multiend package, the process
comprising: A) melt-spinning two or more compositionally different
polyesters from multiple pre-coalescent or post-coalescent
spinnerets in a single spinning position to form multiple
side-by-side or eccentric sheath-core polyester bicomponent
filaments; B) grouping the filaments into at least two threadlines,
each threadline consisting of multiple filaments; C) taking up the
threadlines at speeds greater than about 300 meters per minute; D)
interlacing each threadline; E) combining multiple groups of at
least two threadlines into multiple threadline bundles; and F)
winding each threadline bundle onto a tube core using conventional
multi-package winders; wherein each threadline bundle is separable
into at least two threadlines and the bicomponent filament
comprises poly(trimethylene terephthalate) and at least one polymer
selected from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members.
5. The process of claim 4, further comprising drawing the
threadlines with a draw ratio greater than about 1.2 and winding
the threadline bundle at speeds greater than about 420 meters per
minute.
6. The process of claim 5, further comprising heat-treating the
threadlines at a temperature between about 100.degree. C. and about
200.degree. C.
7. A process for producing a multiend package, the process
comprising A) forming at least two threadlines from two or more
side-by-side or eccentric sheath-core polyester bicomponent
filaments; B) combining the threadlines into a threadline bundle;
and C) winding the threadline bundle onto a tube core; wherein the
threadline bundle is separable into at least two threadlines and
the bicomponent filament comprises poly(trimethylene terephthalate)
and at least one polymer selected from the group consisting of
poly(ethylene terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
8. The process of claim 7, wherein the package has dimensions
appropriate for direct use in making core spun yarn.
9. The process of claim 8, wherein the package has dimensions to
fit the apparatus for core spinning spandex yarn.
10. The process as in one of claims 1-9, wherein the bicomponent
filament comprises poly(ethylene terephthalate) and
poly(trimethylene terephthalate).
11. The process as in one of claims 1-9, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(trimethylene terephthalate).
12. The process as in one of claims 1-9, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(tetramethylene terephthalate).
13. A threadline bundle comprising at least two threadlines, each
threadline comprising multiple side-by-side or eccentric
sheath-core polyester bicomponent filaments, wherein the threadline
bundle is separable into at least two threadlines, and the
bicomponent filament comprises poly(trimethylene terephthalate) and
at least one polymer selected from the group consisting of
poly(ethylene terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
14. The threadline bundle of claim 13, wherein the filaments have a
cross-section shape selected from the group consisting of round,
oval, or snowman or a combination of such members.
15. The threadline bundle of claim 13, wherein the filaments have a
non-round cross-section shape.
16. The threadline bundle of claim 13, wherein the denier of each
threadline is between about 10 and about 300.
17. The threadline bundle of claim 13, wherein the denier per
filament is between about 0.50 and about 20.
18. The threadline bundle of claim 13, wherein the threadline has a
crimp potential of at least 30%.
19. The threadline bundle of claim 13, wherein the bicomponent
filament comprises poly(ethylene terephthalate) and
poly(trimethylene terephthalate).
20. The threadline bundle of claim 13, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(trimethylene terephthalate).
21. The threadline bundle of claim 13, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(tetramethylene terephthalate).
22. A multiend package comprising a threadline bundle wound onto a
tube core, wherein the threadline bundle is separable into at least
two threadlines, each threadline comprising multiple side-by-side
or eccentric sheath-core polyester bicomponent filaments, and the
bicomponent filament comprises poly(trimethylene terephthalate) and
at least one polymer selected from the group consisting of
poly(ethylene terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
23. The package of claim 22, wherein the package has dimensions
appropriate for direct use in making core spun yarn.
24. The multiend package of claim 22 or 23 wherein the bicomponent
filament comprises poly(ethylene terephthalate) and
poly(trimethylene terephthalate).
25. The multiend package of claim 22 or 23, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(trimethylene terephthalate).
26. The multiend package of claim 22 or 23, wherein the bicomponent
filament comprises poly(trimethylene terephthalate) and
poly(tetramethylene terephthalate).
27. The multiend package made by the process of claim 1 or 4 or
7.
28. The threadline bundle of the multiend package made by the
process of claim 1 or 4 or 7.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a multiend package of
multicomponent yarns, the yarn being separable into individual ends
upon unwinding. More specifically, this invention relates to a
multiend package of polyester bicomponent continuous filament
yarns, and the separable yarns on such a package. The invention
also relates to a method of making the multiend package of
separable polyester bicomponent continuous filament yarns.
BACKGROUND OF THE INVENTION
[0002] Typically, filament yarn production involves extruding
multiple filaments from a spinneret, then either combining all the
filaments into a single threadline which is then wound onto a
single package, or dividing the filaments into multiple filament
threadlines which are then each wound onto single packages. In
either case, one multicomponent threadline is wound onto one
package. This is also known as having one "end" per package.
[0003] Polyester bicomponent filaments are elastomeric filaments
which have stretch and recovery characteristics due to their
three-dimensional crimp. Polyester bicomponent filaments have been
disclosed, for example in U.S. Pat. No. 3,671,379. High speed
spinning of polyester bicomponent filaments including poly(ethylene
terephthalate) and poly(trimethylene terephthalate) have been
disclosed, for example in U.S. Pat. No. 6,692,687. Single-end
polyester bicomponent fiber packages have been disclosed, for
example in U.S. Pat. No. 6,824,869.
[0004] U.S. Pat. No. 5,524,841 discloses the winding of a plurality
of textile strands or yarns and winding improvements which enhance
the separation of multiple textile strands during unwinding of a
wound package. The invention is suggested to be useful in processes
involving winding of mono- or multifilament natural or synthetic
materials or yarns such as nylon, polyester, boron or carbon fiber
or strands but is discussed generally in the context of its use in
the manufacture and processing of glass fiber.
[0005] U.S. Pat. No. 5,665,293 relates to the field of synthetic
filament production and discloses a method of making spun yarn
packages of multiple individually separable yarn ends. The method
is suitable for melt-spinnable polymers, disclosed in the patent to
be nylons such as nylon-6 and nylon-6,6, polyesters, and
polyolefins such as polypropylene.
[0006] U.S. Pat. Nos. 6,562,456 and 5,723,080 disclose an elastane
multifilament yarn which is splittable into individual filaments
when unwound from a bobbin, and a process for producing such
yarn.
[0007] Conventionally, a 165 dtex yarn with 68 filaments of
polyester bicomponent continuous filament is extruded from a
spinneret, after quenching, oiling, drawing, interlacing, the
single threadline with 165 dtex-68 filaments is wound into a
tube--single end package.
[0008] A multiend package of yarn, that is, a single yarn package
on which two or more ends of yarn have been wound, would be a way
to significantly increase yarn manufacturing productivity while
decreasing investment intensity and cost of manufacture. A multiend
package of yarn would also be beneficial for reducing the cost of
downstream processing operations such as beaming or core spinning
because less equipment and capital investment would be required.
However, the technical challenges of producing a multiend package
in which the yarns are consistently separable upon unwinding are
considerable, particularly for bicomponent continuous filament
yarns which have crimp and stretch and recovery properties.
Nevertheless, methods to prepare multiend packages of separable
polyester bicomponent yarns are sought, as are the separable yarns
themselves.
SUMMARY OF THE INVENTION
[0009] In some embodiments is a process for producing a multiend
package, the process including:
A) melt-spinning two or more compositionally different polyesters
from a single pre-coalescent or post-coalescent spinneret to form
multiple side-by-side or eccentric sheath-core polyester
bicomponent filaments; B) grouping the filaments into at least two
threadlines, each threadline including more than one filaments; C)
taking up the threadlines at speeds greater than about 300 meters
per minute; D) interlacing each threadline; E) combining the
threadlines into a threadline bundle; and F) winding the threadline
bundle onto a tube core at speeds greater than about 300 meters per
minute; wherein the threadline bundle is separable into at least
two individual threadlines and the bicomponent filament comprises
poly(trimethylene terephthalate) and at least one polymer selected
from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members.
[0010] In another embodiment is a process for producing a multiend
package, the process including:
A) melt-spinning two or more compositionally different polyesters
from multiple pre-coalescent or post-coalescent spinnerets in a
single spinning position to form multiple side-by-side or eccentric
sheath-core polyester bicomponent filaments; B) grouping the
filaments into at least two threadlines, each threadline consisting
of multiple filaments; C) taking up the threadlines at speeds
greater than about 300 meters per minute; D) interlacing each
threadline; E) combining multiple groups of at least two
threadlines into multiple threadline bundles; and F) winding each
threadline bundle onto a tube core using conventional multi-package
winders; wherein each threadline bundle is separable into at least
two threadlines and the bicomponent filament comprises
poly(trimethylene terephthalate) and at least one polymer selected
from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members.
[0011] In a further embodiment is a process for producing a
multiend package, the process including:
A) forming at least two threadlines from two or more side-by-side
or eccentric sheath-core polyester bicomponent filaments; B)
combining the threadlines into a threadline bundle; and C) winding
the threadline bundle onto a tube core; wherein the threadline
bundle is separable into at least two threadlines and the
bicomponent filament comprises poly(trimethylene terephthalate) and
at least one polymer selected from the group consisting of
poly(ethylene terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
[0012] Also included is a threadline bundle including at least two
threadlines, each threadline includes multiple side-by-side or
eccentric sheath-core polyester bicomponent filaments, wherein the
threadline bundle is separable into at least two threadlines, and
the bicomponent filament includes poly(trimethylene terephthalate)
and at least one polymer selected from the group consisting of
poly(ethylene terephthalate), poly(trimethylene terephthalate), and
poly(tetramethylene terephthalate) or a combination of such
members.
[0013] An additional embodiment provides a multiend package
including a threadline bundle wound onto a tube core, wherein the
threadline bundle is separable into at least two threadlines, each
threadline including multiple side-by-side or eccentric sheath-core
polyester bicomponent filaments, and the bicomponent filament
comprises poly(trimethylene terephthalate) and at least one polymer
selected from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic representation of the yarn spinning
and winding system of some embodiments.
[0015] FIG. 2 is a schematic representation a side view of a high
speed winder used with spinning and winding system of some
embodiments.
[0016] FIG. 3 is a schematic representation of the preparation of
core-spun polyester bicomponent from a multi-end package.
[0017] FIG. 4 is a schematic representation of hollow spindle
covering using polyester bicomponent from a multi-end package.
[0018] FIG. 5 is a schematic representation of a knitting process
using polyester bicomponent from a multi-end package.
DETAILED DESCRIPTION OF THE INVENTION
[0019] It has now been found that a package comprising multiple
ends of polyester bicomponent filament yarn can be made in such a
way that the yarn is separable into multiple individual
threadlines, each threadline comprising multiple bicomponent
filaments, upon unwinding. The multiend package can be used
directly in processes such as beaming, circular knitting, weaving,
or core spinning in place of multiple single end packages, which
provides convenience and cost savings. The bicomponent filament
comprises poly(trimethylene terephthalate) and at least one polymer
selected from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members.
[0020] For the purposes of the present invention, the following
terms are defined below:
[0021] POY (Partially Oriented Yarn): Filament yarns in which the
draw ratio is less than normal so that only partial longitudinal
orientation of the polymer molecules.
[0022] FDY (Fully Drawn Yarn): As opposed to POY, filament yarns in
which the draw ratio is normal so that full longitudinal
orientation of polymer molecules.
[0023] DW (Draw Winding): The operation of stretching continuous
filament yarn to align of order molecular and crystalline
structure. The drawn yarn is taken up on a parallel tube or cheese,
resulting in a zero-twist yarn.
[0024] DTY (Draw Texturing Yarn): Filament yarn in which the
manufacture is the simultaneous process of drawing to increase
molecular orientation and imparting crimp to increase bulk.
[0025] DT (Draw Texturing): In the manufacture of thermoplastic
fibers, the simultaneous process of drawing to increase molecular
orientation and imparting crimp to increase bulk.
[0026] Multiple: Having or involving many individuals, filaments,
threadlines and ends.
[0027] Multifilament: A yarn consisting of many continuous
filaments or strands, as opposed to monofilament which is one
strand. Most textile filament yarns are multifilament.
[0028] Multicomponent: The fiber is composed of more than one
polymer. In some embodiments, these polymers are primarily
poly(ethylene terephthalate) (2GT), poly(trimethylene
terephthalate) (3GT), and poly(tetramethylene terephthalate) (4GT)
or a combination of such members.
[0029] Core Spun Yarn: A yarn made by twisting fibers around a
filament, thus concealing the core. One example is where the core
yarn is an elastic yarn (such as 2GT 3GT bicomponent) to obtain
stretch-recovery characteristics and twisting fibers are cotton
fibers to obtain desirable touch aesthetic.
[0030] Dimensions appropriate for direct use in making core spun
yarn: Conventionally, the core yarn for CSY (Core Spun Yarn) is
spandex yarn, which packages size is much smaller than polyester
bicomponent yarn. Therefore, the creel or space in the CSY machine
is not available for placing one yarn package on one spinning
position when polyester bicomponent yarn replacing spandex
yarn.
[0031] Elastomeric fiber: Synthetic fibers having properties of
natural rubber such as high stretchability and recovery.
[0032] Hard yarn: As opposed to elastomeric fiber, synthetic fibers
having no properties of natural rubber such as stretchability and
recovery.
[0033] Spandex: A manufactured fiber in which the fiber-forming
substance is a long chain synthetic polymer composed of at least
85% of a segmented polyurethane.
[0034] As used herein, "bicomponent filament" means a continuous
filament in which two polymers of the same general class are
intimately adhered to each other along the length of the fiber, so
that the fiber cross-section is for example a side-by-side,
eccentric sheath-core, or other suitable cross-section from which
useful crimp can be developed.
[0035] As used herein, "side-by-side" means that the two components
of the bicomponent fiber are immediately adjacent to one another
and that no more than a minor portion of either component is within
a concave portion of the other component. "Eccentric sheath-core"
means that one of the two components completely surrounds the other
component but that the two components are not coaxial.
[0036] As used herein, "threadline" means a group of two or more
bicomponent filaments. The filaments of the threadline are
processed together, as a group. As used herein, "end" means an
individual fiber, yarn, or threadline. As used herein, "threadline"
is interchangeable with "end". In conventional fiber spinning and
winding processes, a single threadline is typically wound onto a
single tube core to produce a "single end" package. The single end
package produced by the conventional procedure is also referred to
as "one end per package."
[0037] As used herein, "threadline bundle" means at least two
threadlines which have been combined together to form one
multicomponent entity, the threadline bundle. The threadline bundle
remains capable of being separated into at least two individual
threadlines (ends). As used herein, threadline bundle also means a
yarn which is comprised of at least two ends.
[0038] As used herein, "yarn" means a continuous strand of textile
fibers, filaments, or material in a form suitable for knitting,
weaving, or otherwise intertwining to form a textile fabric.
[0039] As used herein, "multiend package" means a threadline bundle
wound onto a tube core.
[0040] The polyester bicomponent filament comprises
poly(trimethylene terephthalate) and at least one polymer selected
from the group consisting of poly(ethylene terephthalate),
poly(trimethylene terephthalate), and poly(tetramethylene
terephthalate) or a combination of such members, in a weight ratio
of from about 30:70 to about 70:30. The polymers may be, for
example, poly(ethylene terephthalate) and poly(trimethylene
terephthalate), poly(trimethylene terephthalate) and
poly(tetramethylene terephthalate), or poly(trimethylene
terephthalate) and poly(trimethylene) terephthalate, for example of
different intrinsic viscosities, although different combinations
are also possible. Alternatively, the compositions can be similar,
for example a poly(trimethylene terephthalate) homopolyester and a
poly(trimethylene terephthalate) copolyester, optionally also of
different viscosities. Other polyester bicomponent combinations are
also possible, such as poly(ethylene terephthalate) and
poly(tetramethylene terephthalate), or a combination of
poly(ethylene terephthalate) and poly(ethylene terephthalate), for
example of different intrinsic viscosities, or a poly(ethylene
terephthalate) homopolyester and a poly(ethylene terephthalate)
copolyester. As used herein, the notation "//" is used to separate
the two polymers used in making a bicomponent filament. Thus, for
example, "poly(ethylene terephthalate)//poly(trimethylene
terephthalate)" indicates a bicomponent filament comprising
poly(ethylene terephthalate) and poly(trimethylene
terephthalate).
[0041] One or both of the polyesters can be copolyesters, and
"poly(ethylene terephthalate)," "poly(tetramethylene
terephthalate)", and "poly(trimethylene terephthalate)" include
such copolyesters within their meanings. For example, a
copoly(ethylene terephthalate) can be used in which the comonomer
used to make the copolyester is selected from the group consisting
of linear, cyclic, and branched aliphatic dicarboxylic acids (and
their diesters) having 4-12 carbon atoms (for example butanedioic
acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and
1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids
(and their diesters) other than terephthalic acid and having 8-12
carbon atoms (for example isophthalic acid and
2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched
aliphatic diols having 3-8 carbon atoms (for example 1,3-propane
diol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol,
2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and
1,4-cyclohexanediol); and aliphatic and araliphatic ether glycols
having 4-10 carbon atoms (for example, hydroquinone
bis(2-hydroxyethyl)ether, or a poly(ethyleneether) glycol having a
molecular weight below about 460, including diethyleneether
glycol). The comonomer can be present to the extent that it does
not compromise the benefits of the invention, for example at levels
of about 0.5-15 mole percent based on total polymer ingredients.
Isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propane
diol, and 1,4-butanediol are exemplary comonomers.
[0042] The copolyester(s) can also be made with minor amounts of
other comonomers, provided such comonomers do not have an adverse
effect on the physical properties of the fiber. Such other
comonomers include 5-sodium-sulfoisophthalate, the sodium salt of
3-(2-sulfoethyl) hexanedioic acid, and dialkyl esters thereof,
which can be incorporated at about 0.2-5 mole percent based on
total polyester. For improved acid dyeability, the (co)polyester(s)
can also be mixed with polymeric secondary amine additives, for
example poly(6,6'-imino-bishexamethylene terephthalamide) and
copolyamides thereof with hexamethylenediamine, preferably
phosphoric acid and phosphorous acid salts thereof. Small amounts,
for example about 1 to 6 milliequivalents per kg of polymer, of
tri- or tetra-functional comonomers, for example trimellitic acid
(including precursors thereto) or pentaerythritol, can be
incorporated for viscosity control.
[0043] The polyester bicomponent filament can also comprise
conventional additives such as antistats, antioxidants,
antimicrobials, flameproofing agents, lubricants, dyestuffs, light
stabilizers, and delustrants such as titanium dioxide as long as
they do not detract from the benefits of the invention.
[0044] There is no particular limitation on the outer cross-section
shape of the bicomponent filament, which can be non-round, round,
substantially oval, triangular, "snowman," and the like. As used
herein, "substantially oval" means that an area of a cross-section
of the filament, measured perpendicular to the longitudinal axis of
the fiber, deviates by less than about 20% from that of an oval
shape. The general term "oval" includes "ovoid" (egg-shaped) and
"elliptical" within its meaning. Such a shape typically has two
axes at right angles through the center of the shape, a major axis
(A), and a minor axis (B), where the length of the major axis A is
greater than the length of the minor axis B. In the special case of
a perfect ellipse, the oval is described by a locus of points whose
sum of whose distances from two foci is constant and equal to A. In
the more general case of an ovoid, one end of the oval can be
larger than the other, so that the sum of the distances from two
foci is not necessarily constant and can vary by 20% or more from
elliptical. As used herein, a "snowman" cross-section shape can be
described as a side-by-side cross-section having a long axis, a
short axis, and at least two maxima in the length of the short axis
when plotted against the long axis.
[0045] The cross-section periphery of the bicomponent filament may
have or may lack constant curvature. The cross-section shape of the
bicomponent filament may have or may lack grooves in the
cross-section periphery. Examples of cross-section shapes which
have grooves are "snowman," "scalloped-oval," and "keyhole."
[0046] As used herein, "polymer interface" means the boundary
between the polymers of the bicomponent filament. The polymer
interface may be substantially linear or curved. For cross-section
shapes having a major and minor axis, the bicomponent filament may
have a polymer interface substantially perpendicular to or
substantially parallel to the major axis of the cross-section.
[0047] The bicomponent filament has a crimp potential from about
30% to about 90%, for example from about 60% to about 80%. The
crimp comes from different shrinkage of polymers, bi-component
fiber is made from different polymers and develops crimp as a
result of the different shrinkage rates. Specifically, the crimp is
maximized upon application of heat to the bicomponent filament.
[0048] Different colors of polyester yarn may be included in some
embodiments. Color can be added to polyester by the use of dyes
and/or pigments. For example, black yarn may be prepared by the
addition of carbon black. These additives are generally added into
polymers and mixed together before passing through the
spinneret.
[0049] FIG. 1 shows one embodiment of a yarn spinning apparatus 10
for providing a process for producing a multiend package which
includes melt spinning two or more compositionally different
polymers 12A and 12B from a single precoalescent or post-coalescent
spinneret 14 to form multiple side-by-side or eccentric sheath-core
polyester bicomponent filaments. A plurality of yarn ends6a-16f is
produced each including of multiple filaments. Finish may be
supplied by a spin finish applicator 19. The yarn ends 16a-16f pass
through the quench cabinet 18. The yarn ends may then be drawn at
G1-G3 and passed through an interlacer 20 including a pressurized
fluid. Two or more of the yarn ends are then combined at a
convergence guide to form multiend bundles and wound onto packages
28a. These multiend bundles can be separated in to the original
yarn ends.
[0050] FIG. 2 provides more detail. Each of 16a and 16b, 16c and
16d, and 16e and 16f are combined to form multiend bundles 24c,
24b, and 24a, respectively, which are wound to form multiend
packages 28c, 28b, and 28a, respectively. When the package is
placed on the creel for unwinding, two threadlines are available
from each multiend package. Each of these threadlines are available
to go to different spinning positions for downstream
processing.
[0051] The features and advantages of the present invention are
more fully shown by the following examples which are provided for
purposes of illustration, and are not to be construed as limiting
the invention in any way.
EXAMPLES
Example 1
Multiend Package of 2 Threadlines of 55 dtex and 34 Filaments
[0052] In order to prepare a multiend package of two threadlines
each of 55 dtex and 34 filaments, each threadline with 68 filaments
is prepared from a single spinneret and separated into two
threadlines with 34 filaments each. Then, each threadline has 34
filaments. For a yarn spinning apparatus with six spinnerets, the
six threadlines become twelve threadlines at one spinning
position.
[0053] Each threadline (12 total with 34 filaments each) has its
own yarn path on rolls and all facilities. All 12 threadlines are
independent. After passing through the interlace jet, 2 threadlines
converge into one threadline by a convergent guide, then this
converged threadline is wound to one yarn package by take up
winder. This provides six multiend packages with each having two
ends from threadlines having 55 dtex and 34 filaments each.
Example 2
Multiend Package of 2 Threadlines of 27 dtex and 17 Filaments
[0054] In order to prepare a multiend package of two threadlines
each of 27 dtex and 17 filaments, each threadline with 34 filaments
is prepared from a single spinneret and separated into two
threadlines with 17 filaments each. Then, each threadline has 17
filaments. For a yarn spinning apparatus with six spinnerets, the
six threadlines become twelve threadlines at one spinning
position.
[0055] Each threadline (12 total with 17 filaments each) has its
own yarn path on rolls and all facilities. All 12 threadlines are
independent. After passing through the interlace jet, 2 threadlines
converge into one threadline by a convergent guide, then this
converged threadline is wound to one yarn package by take up
winder. This provides six multiend packages with each having two
ends from threadlines having 27 dtex and 17 filaments each.
Example 3
Multi-End Package for Core Spinning
[0056] FIG. 3 shows a multiend package 28c for core spinning
process. The yarn is driven by two delivery rollers 38 so that the
two multicomponent yarns 16a and 16b from multiend package 28c are
separated and unwound tangentially to the roller guides 30 which
direct the separated multicomponent yarn 16a and 16b to its
corresponding front roller 35 of spinning position where the
polyester multiple component yarns are combined with the staple
roving fiber 2 to provide separate core-spun yarn packages 4.
Example 4
Multi-End Package for Hollow Spindle Covering
[0057] FIG. 4 shows a multiend package for hollow spindle covering
process. The multiend package 28 is driven by two delivery rollers
38 and the two multicomponent yarns 16a and 16b are delivered
tangentially to individual guide eyelets 42 of corresponding
spinning position. The separated multicomponent yarns 16a and 16b
separately pass from second delivery rollers 40 than pass through a
spinning spindle 44 which has a hollow tube at the center and
carries a non-elastic yarn package outside 46. The spinning action
of the spindle releases the non-elastic yarn and wraps around the
multicomponent yarn and is taken up by third delivery rollers 41 to
a covered package 48 for other applications.
Example 5
Multi-End Package for Circular Knitting
[0058] FIG. 5 shows a multiend package 28 for circular knitting.
The multiend yarns 16a and 16b on the package 28 are delivered by
two delivery rollers 38 at a constant speed and separated to
individual stop motion devices 54 for corresponding knitting
position. The separated yarns 16a and 16b pass from roller guides
50 to a yarn feeder 52 to the knitting needles 58. Separately, hard
yarn packages 60 provide hard yarn with a feed speed control
apparatus 56 to the yarn feeder 52 for knitting a garment or fabric
including a hard yarn and an elastic bicomponent yarn.
[0059] Examples 3, 4, and 5 have a device which drives the multiend
package at a constant and pre-determined speed to deliver the
multicomponent yarn tangentially. The draft of multicomponent yarn:
delivery speed of the multiend package relative to that of
non-elastic yarns, is normally at a range of 1.times. to
1.2.times., typically 1.01.times. to 1.1.times. for better
processing efficiency.
[0060] While there have been described what are presently believed
to be the preferred embodiments of the invention, those skilled in
the art will realize that changes and modifications may be made
thereto without departing from the spirit of the invention, and it
is intended to include all such changes and modifications as fall
within the true scope of the invention.
* * * * *