WO2019038784A1 - Fils entrelacés séparables multiplis, leurs procédés de fabrication et étoffes textiles tissées de ceux-ci - Google Patents

Fils entrelacés séparables multiplis, leurs procédés de fabrication et étoffes textiles tissées de ceux-ci Download PDF

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Publication number
WO2019038784A1
WO2019038784A1 PCT/IN2018/050539 IN2018050539W WO2019038784A1 WO 2019038784 A1 WO2019038784 A1 WO 2019038784A1 IN 2018050539 W IN2018050539 W IN 2018050539W WO 2019038784 A1 WO2019038784 A1 WO 2019038784A1
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Prior art keywords
yarn
ply
yarns
separable
filament
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PCT/IN2018/050539
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English (en)
Inventor
Ronak Rajendra GUPTA
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Gupta Ronak Rajendra
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Publication of WO2019038784A1 publication Critical patent/WO2019038784A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/08—Interlacing constituent filaments without breakage thereof, e.g. by use of turbulent air streams
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/12—Stretch-spinning methods
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • D01F6/625—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters derived from hydroxy-carboxylic acids, e.g. lactones
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/18—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by combining fibres, filaments, or yarns, having different shrinkage characteristics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/20—Combinations of two or more of the above-mentioned operations or devices; After-treatments for fixing crimp or curl
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/008—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft characterised by weave density or surface weight
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/49—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads textured; curled; crimped
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/088—Cooling filaments, threads or the like, leaving the spinnerettes
    • D01D5/092—Cooling filaments, threads or the like, leaving the spinnerettes in shafts or chimneys

Definitions

  • the present disclosure relates to the field of textiles. More particularly, the present disclosure relates to multi-ply separable filament yarns and multi-ply separable textured yarns and a method to manufacture it.
  • Textile manufacturing industry includes conversion of fiber or filaments into yarn and from yarn to fabric that is further processed.
  • filament yarn is produced by melting and extrusion of polymer chips in an extruder or directly from polymer melt coming from a continuous polymerization plant.
  • Polymer may be a polyester, polyamide, polypropylene, polytri methylene terephthalate, Polybutylene terephthalate, etc.
  • Polymer melt is pressed through holes in spinnerets to form streams that are quenched to form filaments.
  • the filaments are grouped to form a filament yarn with desired evenness, strength, shrinkage, elongation and other properties.
  • the filament yarns may be oriented or drawn to form low, medium, partially, high, fully oriented or fully drawn yarn.
  • Textured filament yarn includes draw textured yarn and air textured yarn (together 3 ⁇ 4 DTY _) etc.
  • the filament yarn is given an texture either by false twisting in an false twist unit wherein twisting and detwi sting takes place or by an fluid like air.
  • Textured yarn is mainly used in weaving & knitting of fabrics for making clothes outer/inner garments, skin-clinging garments, home furnishings, seat covers, bags upholstery, bed sheets and many other uses.
  • Multi-ply yarns are basically two or more yarns plyed together. Each yarn in the multi-ply may be referred to as a ply. Multi-ply yarns may be untwisted or unplyed to an individual ply.
  • Interlaced yarns The yarns during processing may be passed through interlacing jets to interlace the filaments within the yarn. Such yarns are referred herein as " Interlaced yarns_. Interlacing helps to bind the filaments within the yarns.
  • Separable interlaced yarn_ as referred herein is a single ply interlaced yarn and that can be split/ unplyed from the multi-ply yarns.
  • N on- separable yarn_ as referred herein is single ply yarn that cannot be split/ unplyed from the multi-ply yarns.
  • Multi-ply separable interlaced filament yarn as referred herein is a multi-ply yarn that is separable in to at least two separable interlaced filament yarn, wherein the interlacing of the filaments within each separable interlaced filament yarn is retained during further processing of the yarn to fabric and in the fabric.
  • Multi-ply separable textured yarn is a multi-ply yarn that is separable in to at least two separable interlaced textured yarn, wherein the interlacing of the filaments within each separable interlaced draw textured yarn is retained during further processing of the yarn to fabric and in the fabric.
  • Separable interlaced yarns are used amongst other in bed sheets wherein fine and super fine separable interlaced yarns are used to increase the thread count of the fabric.
  • Thread count is the number of threads woven into one square inch of fabric. This number is based on the threads woven horizontally ("weft") and vertically ("warp"). Weft insertions in an fabric are called as " picks , . Thread count is increased by using multi-ply separable draw textured yarns and inserting in the weft. For example a Thread count of 1100 could be formed by taking 200 yarns per inch of any material in the warp say 50s cotton and inserting in weft 75 picks per inch in the weft and each pick will have 12 ply separable textured yarn. So, the weft would have 900 (75*12) yarns per inch and total thread count is 1100 (900+200). Accordingly the warp may also have multi-ply separable yarns to achieve very high thread counts.
  • filament yarn is fed through a feed roller and passed through a heater, cooling plate and a false-twist unit having disks where the twisting and de- twisting, also known as false twisting takes place at a high speed.
  • the yarn is further passed through an intermediate roller or a :draw roller " .
  • the draw roller draws the yarn while it is heated in the primary heater and getting twisted and de- twisted in the false-twist unit. This gives the yarn the required bulkiness or f I uff i ness, al so referred to as texturi z i ng.
  • the yarn is then passed through interlacing jets to i nterlace the fi laments withi n the yarn.
  • two or more texturized yarns are wound/plied/grouped together in a single bobbin after passing through an interlacing process. Since the filaments of each yarn are interlaced, each yarn ply gets separated resulting in multi-ply separable textured yarns.
  • the textured yarns are produced on a textured machine.
  • a texture machine there are " X _ number of spindles, and " X _ number of textured packages are formed at a time if no plying is done.
  • the number of packages formed at a time is ' X _ divided by the number of plies.
  • n_ ply separable textured yarns are made having d_ denier of ply yarns
  • the number of textured yarn packages that is made is X/n. This requires _ number of filament yarn packages and the denier of the wound yarn is d*n.
  • the other remaining ply or plies are also required have to be broken, which makes the industrial process inefficient.
  • the document discloses multiend packages of multi component yarns, where the yarn is separable into individual ends upon unwinding.
  • the multi component yarn may be a bi-component yarn, such as a yarn including compositional ly different polyesters in a side-by-side or eccentric sheath-core configuration.
  • the document further discloses a process for producing a multiend package, wherein the process comprises melt-spinning two or more compositional ly different polyesters from a single pre- coal esc ent or post- coalescent spinneret to form multiple side-by-side or eccentric sheath-core polyester bi-component filaments
  • the conventional system and/or method of manufacturing multi-ply separable textured yarn has inherent issues such as low productivity, high production cost per kilogram of yarn of a particular denier, and poor capability produce low/fine and ultra-low/fine denier yarns.
  • the present disclosure provides means to solve at least one of the aforementioned problems through its various aspects and embodiments.
  • the multi-ply separable yarn comprising a plurality of filament yarns, wherein at least one filament yarn comprises a plurality of filaments separably interlaced to each other and has a denier in a range from 3 to 9.
  • the multi-ply separable yarn can be a textured yarn and is a polymeric material including a polyester, polyamide, polypropylene, polytri methylene terephthalate,
  • the second aspect provides a multi-ply separable interlaced yarn comprising a plurality of filament yarns, wherein at least one filament yarn comprises a plurality of filaments separably interlaced to each other and has a denier ranging from 3 to 32, wherein the multi-ply separable yarn is made of bio-polymer including poly-lactic acid.
  • the yarn can be a textured yarn.
  • a woven textile fabric having a plurality of warp and weft yarns, the fabric comprising a plurality of multi-ply separable interlaced yarns as weft yarns, said yarns having a denier in a range from 3-9 providing the woven fabric having a thread count more 2000 threads per square inch.
  • the multi-ply separable yarn can be a textured yarn.
  • a woven textile fabric having a plurality of warp and weft yarns, said fabric comprising a plurality of multi-ply separable interlaced filament yarns made of bio-polymer including poly-lactic acid as the weft yarns, wherein the yarns have a denier in a range from 3 to 32 for providing the fabric having thread count more 400 threads per square inch.
  • the multi-ply separable yarn can be a textured yarn.
  • a method for manufacturing a multi-ply separable interlaced filament yarn from poly-lactic acid polymer comprising steps of: melting poly-lactic acid polymer, passing melt of poly-lactic acid polymer through a spinning unit to form plurality of molten streams at a temperature between 220-280 deg C, cooling the molten streams in a quenching zone to form a plurality of bio-polymer filaments, interlacing the bio-polymer filaments to form a separable interlaced filament bio-polymer yarn and converging two or more separable interlaced filament bio-polymer yarns to provide a multi-ply separable interlaced filament bio-polymer yarn.
  • the step interlacing includes grouping of 7-24 filaments to form a multi-ply interlaced separable filament bio- polymer yarn in a range from 3 to 32 denier.
  • Sixth aspect provides method for manufacturing a multi-ply separable interlaced filament yarn comprising steps of melting a polymeric material, passing melt of polymeric material through a spinning unit to form plurality of molten streams, cooling the molten streams in a quenching zone to form a plurality of polymer filaments, interlacing the filaments to form a separable interlaced filament polymer yarn at a pressure in a range from 7-14 bar and converging two or more separable interlaced filament yarns to provide a multi-ply separable interlaced filament yam.
  • the interlacing step includes grouping of 7-24 filaments to form a multi-ply interlaced separable filament yarn from 3 to 9 denier.
  • FIGU RES 1 and 2 illustrate examples of conventional filament yarn manufacturing
  • FIGU RES 3A , 3 B and 3C ill ustrate vari ous types of i nterl ac i ng of yarns;
  • FIGU RES 4 illustrate example of manufacturing separable interlaced filament yarn using a system and method in accordance with the present disclosure
  • FIGU RES 4A, 4B, 4C, 5A, 5B and 5C illustrate various examples of manufacturing multi-ply separable interlaced filament yarn in a productive manner usi ng a system and method in accordance with the present disclosure
  • FIGU RES 6A illustrate an example of manufacturing multi-ply separable textured yarn using a conventional system
  • FIGU RES 6B and 6C illustrate an example of manufacturing multi-ply separable textured yarn in a productive manner using a system and method in accordance with the present disclosure
  • FIGU RES 7 illustrates a significant gain in Output and Capability by using the system and method of manufacturing in accordance with the present disclosure compared to the conventional way.
  • the additional embodiments and/or aspects with respect to the Patent of additions are a multi-ply separable interlaced yarn having at least one filament yarn of 3-9 denier, a multi-ply separable interlaced yarn made of bio- polymer including poly-lactic acid, a woven textile fabric having a thread count more 2000 threads per square inch, a woven textile fabric having thread count more 400 threads per square inch and comprising plurality of bio polymer multiply separable interlaced filament yarns as weft yarns, a method for manufacturing a multi-ply separable interlaced filament yarn from poly-lactic acid polymer and a method for manufacturing a multi-ply separable interlaced filament yarn having interlacing at a pressure in a range of 7-14 bar.
  • Figures 1 and 2 illustrate conventional method of manufacturing filament yarn, wherein polymer melt is received in a spinning unit (100) via an inlet line (104) and is pressurized or extruded with a melt pump (102) through nozzles (two or more in numbers) in spinnerets (110) placed in a spin pack (108). This results in the generation of two or more polymer filaments (114). These filaments (114) are cooled in a quenching chamber (112) with air in order to solidify. The solidified filaments (114) are bunched in groups of two or more to make a yarn (120).
  • ten filaments (114) are grouped to make one filament yarn (120). In this way, ten yarns (120) are formed.
  • T he f i I ament yarns ( 120) are passed through spi n f i ni sh oi I appl i cator ( 118) , spi n f i ni sh oi I is appl i ed on the yarns ( 120) usi ng a spi n finish pump and spin finish application nozzles to give it oiling/greasing. Spin finish may also be applied using a roller dipped in spin finish oil.
  • the polymer filaments used in accordance to the present invention are not side- by-side or seath-core bi-component fi lament.
  • Y arns may also be plied, i.e., multiple yarns wound or grouped together on a single bobbin to increase the denier of each yarn, or increase the filaments per yarn or improve the quality of the yarn.
  • two filament yarns (120) are plied together to form a 2-ply filament yarn. In this way, five 2-ply filament yarns are formed.
  • the plied yarns are passed through one or more enclosure/device referred to as interlacing/ migration/ interlacing/ comingling/ fluid jets/ nozzles (124), (130), and (132) ( " Interlacing J et_).
  • interlacing/ migration/ interlacing/ comingling/ fluid jets/ nozzles 124), (130), and (132)
  • Interlacing J et_ the filaments of the yarn are subjected to a pressured fluid passed through one or more nozzles from fluid inlet pi pe ( 126), to achi eve one or more of the f ol I owi ng obj ects: I Interlacing of filaments with each other;
  • interlacing is carried out at fluid pressure of 1 to 3 bar for filament yarns. Interlacing results in better processing speeds in filament yarn manufacturing, improves bobbin package build, even distribution of spin finish, reduces filaments and yarn breaks.
  • the interlaced yarns are represented by B.
  • the number of interlacing jets per yarn may vary in the entire yarn path (nil to many). In Figure 1 such varying sets of interlacing jets are shown.
  • separator rollers also referred to as godets.
  • separator rollers also referred to as godets.
  • two such separator rollers (128), (134) are provided for good quality of filament yarn.
  • the number of separator rollers may vary depending upon the requirement.
  • the separator rollers help achieve the following objectives amongst others:
  • the interlaced yarns are sent to a winder (136) provided with one or more bobbins (also referred to as tubes or cones) (140). Each interlaced yarn is wound around a discrete bobbin.
  • the winder may have a capacity to wind yarn on 10 bobbins at a time.
  • Reference numeral (138) denotes the number of bobbi s (140) of yarn wounded i each case.
  • Figure 2 illustrate manufacturing of the filament yarns without plying to form filament yarn.
  • five filament yarns are formed.
  • the filaments of yarn are subjected to pressurized fluid between 1 to 3 bar in the interlacing jets, resulting in interlaced yarns and are wound directly.
  • 5 single interlaced filament yarns are wound onto 5 bobbins.
  • Figures 3A, 3B, and 3C illustrate effects of intermingling or interlacing of filaments of a yarn, when the yarn is passed through the interlacing jet having pressured fluid jet.
  • an arrow head represents the flow of pressurized fluid through a nozzle or Interlaci g J et (124), (130), (132), shown as a block. This results in knotting or intermingling or interlacing or comingling or bonding of the filaments of yarn.
  • the intensity or strength of interlacing can be varied with amongst others, the changing of fluid pressure, nozzle diameter and the number of nozzles, nozzle angle, etc.
  • a filament yarn manufacturing system has plurality of winders 136. Production of a filament yarn line is given by the following formula at 100% Efficiency:
  • a method of manufacturing a separable interlaced filament yarn comprising:
  • step interlacing includes grouping of 7-24 filaments to form a multi-ply interlaced separable filament yarn from 3 to 9 denier;
  • the present disclosure also provides a method of manufacturing a separable interlaced filament yarn from poly-lactic acid polymer wherein the method comprises steps of
  • the step interlacing includes grouping of 7-24 filaments to form a multi-ply interlaced separable filament bio-polymer yarn i n a range from 3 to 32 denier.
  • Figure 4 illustrate the manufacturing method of separable interlaced filament yarn using method in accordance with the present disclosure.
  • the polymer melt including bio-polymer is received in a spinning unit (100) via an inlet line (104) and is pressurized or extruded with a melt pump (102) through nozzles (two or more in numbers) in spinnerets (110) placed in a spin pack (108).
  • a melt pump (102) through nozzles (two or more in numbers) in spinnerets (110) placed in a spin pack (108).
  • These filaments (114) are cooled in a quenching chamber (112) with air in order to solidify.
  • the solidified filaments (114) are bunched in groups of two or more to make a yarn (120).
  • Ten filaments (114) are grouped to make one filament yarn (120). In this way, ten yarns (120) are formed.
  • the filament yarns (120) are passed through spin finish oil applicator (118), spin finish oil is applied on the yarns (120) using a spin finish pump.
  • the yarns are then passed through one or more enclosure device referred to as interlacing/ migration/ interlacing/ comingling/ fluid jets/ nozzles (124), (130), and (132) ( ' Interlacing J et_).
  • interlacing jet the filaments of yarn are subjected to a pressured fluid passed through one or more nozzles from fluid inlet pipe (126), to achieve one or more of the f ol I owi ng obj ects:
  • Separable interlaced filament yarn is formed by interlacing in such a way that the interlacing remains in further processing of yarn and in the fabric.
  • separable interlaced filament yarns are represented by D.
  • the number of interlacing jets per yarn may vary in the entire yarn path.
  • the interlacing may include grouping of 7-24 filaments to form a multi-ply separabl e f i I ament yarn.
  • the interlaced yarns may be passed through separator rollers (also referred to as godets).
  • separator rollers also referred to as godets.
  • separator rollers Preferably, two such separator rollers (128), (134) are provided for good quality of filament yarn.
  • the number of separator rollers may vary depending upon the requirement. The separator rollers help achieve the following objectives amongst others:
  • the yarns are sent to a winder (136) provided with one or more bobbins (also referred to as tubes or cones) (140). Each yarn is wound around a discrete bobbin.
  • the winder has a capacity to wind yarn on 10 bobbins at a time.
  • Reference numeral (138) denotes the number of bobbins (140) of yarn wounded in each case.
  • the separable interlaced filament yarn is converged with at least one more separable interlaced filament yarn to provide a multi-ply separable interlaced filament yarn.
  • the spinning unit is operated at a reduced temperature preferably between 220-280 deg C.
  • Figures 4A, 4B and 4C illustrate various examples of manufacturing multi-ply separable interlaced filament yarn using a system and method in accordance with the present disclosure.
  • the structural features of the spinning unit (200), common to the spinning unit (200), are obviated for the sake of brevity.
  • the plying of the filament yarn as illustrated in figures 4A, 4B and 4C is done after passing them through at least one interlacing jet (124, 130, and 132) where the combination of fluid pressure, nozzle size, number of nozzles are used in a way that very strong interlacing (bondi ng/ intermingli ng/ comingling/ entangling) between the filaments of a yarn ply takes place and the interlacing does not open during further processing on a texturizing machine and i n fabric resulting in separable interlaced filament yarn.
  • multi-ply separable interlaced filament yarn at various stages are represented by E, G, and I.
  • the multiply interlaced filament yarn can be manufactured with 3 to 9 denier in addition to the denier claimed in the parent patent/ application. Further, the disclosure also allows to manufacture a multi-ply interlaced filament bio-polymer yarn having denier in the range from 3-32.
  • the migration block (302) is either treated as a : bypass " block having no or very little fluid pressure.
  • the interlacing jets (124, 130, and 132) can be placed at any location in the entire yarn path between the spinnerets (110) and the winder (136), for example, as shown in Figure 4A.
  • fluid pressure in the interlacing jets (124, 130, 132) may also be increased/decreased and/or a nozzle diameter of the interlacing jet (124, 130, 132) may be increased/decreased to achieve more strong and effective interlacing of the filaments before plying. Due to this, the filaments of one yarn ply do not mix with the filaments of another yarn ply during processing, and results in a multi-ply, separable filament yam. In each of the cases shown in Figures 4A, 4B and 4C, five packages of 2-ply/ separable interlaced filament yarns are formed. The present disclosure allows to raise the interlacing pressure in a range of 7-14 bar.
  • the output of a particular line producing a particular denier of a ply can be increased manifolds by just increasing the number of interlacing jets in the yarn path.
  • the number of spin finish application nozzles (118) may be increased as necessary. The capital investment of doing this is very low compared to the conventional filament yarn manufacturing process. Further, the increased output also results in reduced production cost per kg of yarn of a particular denier. In fact, the more the number of plies of yarns of a particular denier, more the capacity in a single li e.
  • the output is quadrupled as compared to the rest.
  • the output can be made triple or five times or :x ⁇ times.
  • separable interlaced filament yarn at various stages are represented by K, M and O.
  • J represents two separable interlaced filament yarn grouped between the quenching chamber (112) and the separator roller (134), after the interlacing jet (124) to form a 2- ply separable yarn represented by ⁇ _.
  • L represents four separable interlaced filament yarn grouped between the quenching chamber (112) and the separator roller (134), after the interlacing jet (124), to form a 4-ply separable interlaced yarn represented by
  • N represents four separable interlaced filament yarn grouped between the quenching chamber (112) and the separator roller (134), after the i nterl ac i ng j et ( 124) , to f orm a 4- pi y separabl e i nterl aced represented by ⁇ _ .
  • a filament yarn package (202) is placed on a filament yarn stand creel of a texturizing/DTY machine and filament yarn (203) is fed through a primary input roller (206) or feed roller.
  • a primary heater (208) the filament yarn is oriented and is passed on a cooling plate (210).
  • the cooled yarn is then passed through a false twist unit (212) having disks in which twisting and de-twisting, also known as false twisting, takes place at high speed.
  • a twist unit is also called as a :texturizing spindle " and the capacity of such a machine depends on the number of spindles it has.
  • the yarn is further passed through an intermediate roller (214) or a :draw roller.
  • the draw roller draws the yarn while it is heated in the primary heater and getting twisted and de- twisted in the false- twist unit. This gives the yarn the required bulkiness or fluffiness, also referred to as ' texturize_.
  • the yarn coming out of the draw roller is called as DTY or textured yarn (222).
  • the interlacing (if any) in filament yarn in the conventional method gets majorly opened during the texturing process, as it is very weak. Interlacing of the filament yarn barely remains and not seen in the texturing process. High interlacing is then done on the Texturizing Machine with interlacing/intermingling jets (215) for getting the filaments of yarn interlaced/intermingled/knotted.
  • the yarn is further optionally passed through a secondary heater (216) where the properties of the yarn, such as shrinkage, bulkiness, twist, dyeing, and affinity, are stabilized with the help of an output roller (218).
  • Kgs Number of bobbins wound at a time* Denier of wound yarn * Speed (m/min) * 60 (min)*24 (hours)/ 9000000.
  • the system/method of manufacturing multi-ply, separable textured yarn aims to resolve amongst others issues of low production and low productivity associated with conventional yarn manufacturing.
  • Present disclosure provides a method for manufacturing a multi-ply separable textured yarn, the method comprising:
  • 2 spindles of a texturizing machine is having an output 2 packages (250) of 2- ply separable textured yarns (239) by using 2-ply separable interlaced filament yarns (253) from 2 packages (252).
  • the multi-ply separable interlaced filament yarn is formed by converging at least two separable interlaced filament yarn.
  • 2 spindles of a texturizing machine is having an output 2 packages (250) of 2-ply separable textured yarns (239) by using 2-ply separable interlaced filament yarn (253) from 4 packages of separable interlaced filament yarn(252).
  • total 4 packages of separable interlaced filament yarn are used on 2 spindles to form two numbers of 2-ply separable textured yarns.
  • the output would be of 4- ply separable textured yarns (239) per spindle if two numbers of 2- ply separable interlaced filament yarn (255) would be used for each spindle and output would be 8-Ply separable textured yarns (239) per spindle if two numbers 4-ply separable interlaced filament yarn(255) would be used for each spi ndle.
  • the advantage in the present method of yarn manufacturing is due to the strong binding or interlacing of the filaments of each yarn ply of the resulting interlaced separable filament yarn manufactured in accordance with the present disclosure, which does not completely open and remains during the texturizing process and also the fabric after the fabric is made and finished. Further, each ply remains separate after texturizing and even in the fabric. Moreover, unlike the conventional textured yarn manufacturing process, here, it is important not to give high interlacing by i terlacing jet (215) on the texturizing machine as all filaments of the pi i es of the yarn woul d get i ntermi ngl ed and woul d not remai n separabl e.
  • the present method results in significant increase in production of textured yarns and results in huge cost saving as compared to the conventional process of plying the yarns in texturizing. Further, the efficiency is more in this process, as a ply breakage does not hamper the whole yarn. Furthermore, increased speeds are used as the denier to be processed per spindle increases.
  • At least one multi-ply separable textured yarn is converged with at least one multi-ply separable textured yarn to increase the number of plies and denier.
  • Figure 7 illustrates a significant gain in Output and Capability by using the system and method of manufacturing in accordance with the present disclosure compared to the conventional way.
  • a two 32 denier filament yarns having elongation in range of 125-150 as per conventional process are made at process speed of 3000 MPM and texturized on a texturized machine at draw ratio of 1.7 at process speed of 750 MPM to yield two textured yarn of 20 denier per spindle which are then highly interlaced and finally 2 textured yarns from 2 spindles are wound together on an tube.
  • column 7B1 for producing 20 denier 4- ply separable textured yarns using the conventional method the filament yarn is made using conventional method as in column 7A1. 4 filament yarns are wound together after texturizing in a package resulting in 78 packages formed at a time with winding denier being 80 ( 20 x4 ).
  • the output remains the same as 7A 1.
  • yarn from 2 packages of 2- ply separable interlaced filament yarn having total denier of 64 per yarn package is fed to an spindle of texturizing machine with reference to Figure 6C, total fed denier being 128 per texturizing spindle results in 4- ply separable textured yarns being produced at all 312 spindles at a time and the texturizing production is quadruple compared to conventional way of 7B1.
  • column 7B3 with regards to filament yarn, the process as in column 7A4 is carried out except that 20 numbers separable interlaced filament yarn each having deni er of 32 are wound i n a groups of 4 on the wi nder usi ng 5 bobbi ns to create 4- Ply separable interlaced filament yarn having wound denier 128. And in Column 7B4 with reference to figure 5C using 40 J ets 40 numbers of separable interlaced filament yarn each having denier of 32 are wound on 10 bobbins to get 4-ply separable interlaced filament yarn in accordance with the present disclosure and output is quadrupled for filament yarn.
  • the filament yarn produced as per column 7B3 and 7B4 is loaded on the texturizing machine as shown with reference to figure 6C for one per spindle and at the output is 4- ply separable DTY having total denier .Thus the texturizing production is quadrupled compared to the conventional method as shown in column 7B1.
  • the line output would be about 78 kgs and it is assumed that the line has a minimum capacity of 150 kgs per day. So it would not be possible to produce the filament yarn for 10 denier unless changes are made to reduce its capacity by changing the melt line size, reducing melt pump capacity, reducing residence time, etc.
  • the number of interlacing jets is increased to 2 times or 4 times as shown in Column 7C2 with respect to Figure 5B and Column 7C3 with respect to figure 5C respectively and an output for 16 denier 4-ply separable interlaced filament yarn having total denier of 64 denier with each separable interlaced filament having denier of 16.
  • This filament yarn when used on texturizing machine in accordance with the present disclosure as shown in column 7C2 and 7C3 would give an output of 4 times compared to the output possible using conventional method as shown in column 7C1.
  • the disclosure in an aspect provides a multi-ply separable interlaced yarn comprising a plurality of filament yarns, wherein at least one filament yarn comprises a plurality of filaments separably interlaced to each other and has a denier in a range from 3 to 9.
  • the present disclosure also provides a woven textile fabric having a plurality of warp and weft yarns, the fabric comprising a plurality of multi-ply separable interlaced yarns as weft yarns, said yarns having a denier in a range from 3-9 providing the woven fabric having a thread count more 2000 threads per square i nch. T he yarn may be textured yarn.
  • the present disclosure in another aspect provides a multi-ply separable interlaced yarn comprising a plurality of filament yarns, wherein at least one filament yarn comprises a plurality of filaments separably interlaced to each other and has a denier ranging from 3 to 32, wherein the multi-ply separable yarn is made of bio- polymer including poly-lactic acid.
  • the present disclosure also provides a woven textile fabric having a plurality of warp and weft yarns, said fabric comprising a plurality of multi-ply separable interlaced filament yarns made of bio-polymer including poly-lactic acid as the weft yarns, wherein the yarns have a denier in a range from 3 to 32 for providing the fabric having thread count more 400 threads per square inch.
  • the yarn may be textured yarn.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

L'invention concerne un fil entrelacé séparable multiplis ayant au moins un fil de filament de 3 à 9 deniers, un fil entrelacé séparable multiplis de bio-polymère comprenant de l'acide polylactique, une étoffe textile tissée ayant une contexture supérieure à 2 000 fils par pouce carré, une étoffe textile tissée ayant une contexture supérieure à 400 fils par pouce carré et comprenant une pluralité de fils de filaments entrelacés séparables multiplis de biopolymère en tant que fils de trame, un procédé de fabrication d'un fil de filament entrelacé séparable multiplis à partir d'un polymère d'acide polylactique et un procédé de fabrication d'un fil de filament entrelacé séparable multiplis ayant un entrelacement à une pression dans la plage de 7 à 14 bars.
PCT/IN2018/050539 2017-08-21 2018-08-21 Fils entrelacés séparables multiplis, leurs procédés de fabrication et étoffes textiles tissées de ceux-ci WO2019038784A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5665293A (en) * 1996-03-08 1997-09-09 Basf Corporation Method of making spun yarn packages multiple individually separable yarn ends
EP1058745B1 (fr) * 1998-03-03 2002-02-06 Heberlein Fibertechnology, Inc. Procede de texturation par bulles d'air de fils de filaments continus et dispositif pour l'appret du fil, ainsi que son utilisation
US20110133011A1 (en) * 2008-03-20 2011-06-09 Invista North America S.A.R.L. Multiend package of multifilament polyester bicomponent yarn
US8186390B2 (en) * 2010-07-08 2012-05-29 Venus Group, Inc. Woven fabric having cotton warp and polyester weft yarns
US20120132309A1 (en) * 2010-11-30 2012-05-31 Morris David D Woven textile fabric and innerduct having multiple-inserted filling yarns
US8317826B2 (en) * 2008-10-07 2012-11-27 Korea Institute Of Industrial Technology Absorbable bulky multi-filament draw textured yarn, manufacturing method thereof and medical use using them
US20150259831A1 (en) * 2012-02-20 2015-09-17 Teijin Aramid B.V. Method and apparatus for entangling yarns
CN105970315A (zh) * 2016-06-22 2016-09-28 浙江理工大学 医用聚左旋乳酸熔融纺纤维的制备方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5665293A (en) * 1996-03-08 1997-09-09 Basf Corporation Method of making spun yarn packages multiple individually separable yarn ends
EP1058745B1 (fr) * 1998-03-03 2002-02-06 Heberlein Fibertechnology, Inc. Procede de texturation par bulles d'air de fils de filaments continus et dispositif pour l'appret du fil, ainsi que son utilisation
US20110133011A1 (en) * 2008-03-20 2011-06-09 Invista North America S.A.R.L. Multiend package of multifilament polyester bicomponent yarn
US8317826B2 (en) * 2008-10-07 2012-11-27 Korea Institute Of Industrial Technology Absorbable bulky multi-filament draw textured yarn, manufacturing method thereof and medical use using them
US8186390B2 (en) * 2010-07-08 2012-05-29 Venus Group, Inc. Woven fabric having cotton warp and polyester weft yarns
US20120132309A1 (en) * 2010-11-30 2012-05-31 Morris David D Woven textile fabric and innerduct having multiple-inserted filling yarns
US20150259831A1 (en) * 2012-02-20 2015-09-17 Teijin Aramid B.V. Method and apparatus for entangling yarns
CN105970315A (zh) * 2016-06-22 2016-09-28 浙江理工大学 医用聚左旋乳酸熔融纺纤维的制备方法

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