WO2021079180A1

WO2021079180A1 - An apparatus for producing a plurality of distinct yarns

Info

Publication number: WO2021079180A1
Application number: PCT/IB2019/060516
Authority: WO
Inventors: Sumit Agarwal
Original assignee: Sumit Agarwal
Priority date: 2019-10-24
Filing date: 2019-12-06
Publication date: 2021-04-29

Abstract

An apparatus for producing a plurality of distinct yarns is disclosed. The apparatus includes a hopper configured to remove moisture from polymer and fed to an extruder unit which is configured to melt the polymer and pass through hydro split spinneret to produce the plurality of distinct yarns which further quenched and intermingled to produce torque-free yarns using a texturizing unit. Moreover, the torque-free yarns are wound on a paper tube. The apparatus helps to remove godets to save power.

Description

AN APPARATUS FOR PRODUCING A PLURALITY OF DISTINCT YARNS

This International Application claims priority from a complete patent application filed in India having Patent Application No. 201921043346, filed on October 24, 2019 and titled “AN APPARATUS FOR PRODUCING A PLURALITY OF

DISTINCT YARNS”

BACKGROUND

Embodiment of the present disclosure relates to production of yarn and more particularly to an apparatus for producing a plurality of distinct yarns. Threads are made by combining fibres together, while yarn is made by twisting the threads. Conventionally, the process adopt for the production of yarn is a simple process, but an expensive one. Furthermore, there have been recently proposed processes for producing polyester yams (POY) composed of fine filaments and utilizing high-speed spinning. The polyester fine multifilament yam obtained by the process is already drawn Thereby, uses thereof are limited. However, even under the extremely limited spinning conditions, a phenomenon in which a molten polymer just after extrusion causes droplet breakage and results in yarn breakage as the polymer throughput is reduced tends to occur simply by preventing the melt from direct cooling in a specific distance range as the molten polymer emerges from the spinneret capillary. As a result, there are increasingly frequent cases where the stable spinning is difficult. Further, currently available process or apparatus includes distributed production of the yarn. The raw material has to go through the multiple separate unit to produce the final product which may further result in generation of single yam at a time and may also result in presence of godets in spinning path which lead to increase in power cost.

Hence, there is a need for an improved apparatus for producing a plurality of distinct yams to address the aforementioned issue(s).

BRIEF DESCRIPTION In accordance with an embodiment of the present disclosure, an apparatus for producing a plurality of distinct yams is provided. The apparatus includes an extruder unit configured to receive polymer from a hopper unit and melt the received polymer by passing the polymers through a plurality of temperature zones. The apparatus also includes a continuous polymer filtration unit operatively coupled to the extruder unit. The polymer filtration unit includes a plurality of micron candles configured to remove foreign impurities from melted polymer. The apparatus includes a spinning packs unit operatively coupled to the polymer filtration unit. The spinning packs unit includes a metering pump configured to regulate the flow of purified melted polymer. The spinning packs unit also includes a spinneret chamber operatively coupled to the metering pump. The spinneret chamber is configured to produce the plurality of distinct yarns from the purified melted polymer using a hydraulic splitting process. The apparatus further includes a quenching chamber operatively coupled to the spinning packs unit. The quenching chamber is configured to solidify a molten filament of the plurality of yams by an application of cold air. The apparatus further includes a texturizing unit. The texturizing unit includes one or more intermingling jets including one or more micro holes configured to generate turbulence to the plurality of yams to produce a plurality of torque-free yarns by De-torque jet using a false-twisting technique.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

FIG. 1 is a block diagram of an apparatus for producing a plurality of distinct yams in accordance with an embodiment of the present disclosure; FIG. 2 is a schematic representation of an exemplary embodiment of an apparatus for producing a plurality of distinct yarns of FIG. 1, depicting a spin finish applicator in accordance with an embodiment of the present disclosure;

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

Embodiments of the present disclosure relate to an apparatus for producing a plurality of distinct yam. The apparatus includes an extruder unit configured to receive polymer from a hopper unit and melt the received polymer by passing the polymers through a plurality of temperature zones. The apparatus also includes a continuous polymer filtration unit operatively coupled to the extruder unit. The polymer filtration unit includes a plurality of micron candles configured to remove foreign impurities from melted polymer. The apparatus includes a spinning packs unit operatively coupled to the polymer filtration unit. The spinning packs unit includes a metering pump configured to regulate the flow of purified melted polymer. The spinning packs unit also includes a spinneret chamber operatively coupled to the metering pump. The spinneret chamber is configured to produce the plurality of distinct yarns from the purified melted polymer using a hydraulic splitting process. The apparatus further includes a quenching chamber operatively coupled to the spinning packs unit. The quenching chamber is configured to solidify a molten filament of the plurality of yams by an application of cold air. The apparatus further includes a texturizing unit. The texturizing unit includes one or more intermingling jets including one or more micro holes configured to generate turbulence to the plurality of yams to produce a plurality of torque-free yarns by De-torque jet using a false-twisting technique.

FIG. 1 is a block diagram representation of an apparatus (10) for producing a plurality of distinct yam in accordance with an embodiment of the present disclosure. The apparatus (10) includes a hopper unit (20) configured to receive polymer, where a dryer (30) configured to remove moisture from received polymer. The removal of moisture is required to save the polymer from degradation. In some embodiments, the dryer (30) may include a static mixer which is configured to enable the mixing of the polymer homogeneously. The apparatus (10) further includes extruder unit (40) which is operatively coupled to hopper unit (20). The extruder unit (40) is configured to receive polymer from a hopper unit (20) and melt the received polymer by passing the polymers through a plurality of temperature zones. The extruder unit (40) includes a screw (not shown in FIG. 1) which is rotated along with the dried polymer. In a specific embodiment, the extruder unit (40) may include a plurality of heaters (not shown in FIG. 1) configured to produce the plurality of temperature zones. The plurality of temperature in extruder unit (40) is given to get smooth melting.

Furthermore, the apparatus (10) includes a continuous polymer filtration unit (50) operatively coupled to the extruder unit (40). The continuous polymer filtration unit (50) includes a plurality of micron candles (60) which is configured to remove foreign impurities from melted polymer. In such embodiment, the plurality of micron candles (60) may be a plurality of steel candles of different microns. The continuous polymer filtration unit (50) is configured to filter melted polymer by pushing it with a predefined pressure through the plurality of micron candles (60).

Moreover, the apparatus (10) further includes a spinning packs unit (70) operatively coupled to the continuous polymer filtration unit (50). The spinning packs unit (70) includes a metering pump (80) configured to regulate the flow of purified melted polymer. In one embodiment, the metering pump (80) may include a plurality of precision gears (not shown in FIG. 1) configured to regulate the flow of the purified melted polymer as required (denier). The spinning packs unit (70) also includes a spinneret chamber (90) operatively coupled to the metering pump (80). The spinneret chamber (80) is configured to produce the plurality of distinct yarns from the purified melted polymer using a hydraulic splitting process. In one embodiment, the spinneret chamber (90) may also be configured to again melt the purified polymer if filtered by different micron filter and metallic sand. The hydraulic splitting process result in production of the plurality of yarns in single spinneret. Depending upon requirement four or six yarns may be spun from single spinners known as hydraulic splitting.

In addition, the apparatus (10) further includes a quenching chamber (100) operatively coupled to the spinning packs unit (70). The quenching chamber (100) is configured to solidify a molten filament of the plurality of yarns by an application of cold air. In a specific embodiment, the apparatus (10) may include a DE torque jets which is configured to remove any residual twist in the plurality of yarns. In one embodiment, the apparatus (10) includes a spin finish applicator (110) operatively coupled to the quenching chamber (100). The spin finish applicator (110) includes a spray type applicator configured to enable uniform application of spin finish on the plurality of yams. In such embodiment, the spray type applicator may include a ceramic nozzle (115) as shown in FIG. 2.

Referring back to FIG. 1, the apparatus (10) further includes a texturizing unit (120) which receives the plurality of yams from the quenching chamber (110). The texturizing unit (120) includes one or more intermingling jets (130) including one or more micro holes (not shown in FIG. 1). The one or more micro holes are configured to generate turbulence to the plurality of yams to produce a plurality of torque-free yams using a false-twisting technique. In some embodiments, the texturizing unit (120) may be configured to create one or more nips in the plurality of yarns using the one or more intermingling jets (130). In such embodiment, the one or more intermingling jets (130) may include 1.1 mm diameter with the one or more nips 16 to 18 per meter.

The molten filament yarn includes draw textured yarn and air textured yarn. In the texturizing unit (120), the filament yarn is given a texture either by false twisting in a false twist unit, wherein twisting and de-twisting takes place by compressed air with air pressure approximately 2 bar to 2.6-2.8 bars as per the requirement. The textured yam is mainly used in weaving and knitting of fabrics for making clothes like skin- clinging garments, home furnishings, seat covers, bags upholstery, bed sheets and the like. The texturizing unit (120) includes one or more processes such as plying, multi plying and interlacing. As used herein, “plying” is done by taking two or more strands of yarn (filament yarn or a textured yam) and putting them together. The term “multi plying” as referred herein are basically two or more yams plying together. Each yam in the multi -ply may be referred to as a ply. Multi-ply yarns may be untwisted or un plying to an individual ply. Similarly, the “interlacing” may be defined as the yarns during processing may be passed through interlacing jets to interlace the filaments within the yam. Such yarns are referred herein as multiple distinct yarn or “interlaced yams”. Interlacing helps to bind the filaments within the yarns.

Subsequently, in one embodiment, the apparatus (10) may include a winding unit (140) operatively coupled to the texturizing unit (120). The winding unit (140) is configured to wound the plurality of torque-free yarns on a paper tube (150). Such process increases thread count in the fabric. In some embodiments, the continuous polymer filtration unit (50), the spinneret packs unit (70), the quenching chamber (100) and the texturizing unit (120) may be configured to remove godets from the plurality of produced yarns.

Various embodiments of the apparatus (10) for producing a plurality of distinct yarn as described above enables production of compact yarn by hydro splitting on spinneret and subsequently texturizing the compact yam with De torque jet to produce zero torque yarn. With this apparatus, reduction of power cost is achieved by removing godets from spinning path.

Generally, one spinneret produces one thread, but this apparatus has hydro split so instead one thread, the apparatus may produce multiple thread in single spinnerets for example, spinneret produce 50/14 denier, but the apparatus has produced special precision spinneret which may produce multiple yarns from single spinneret.

In addition, the texturizing process provides texture, crimp, bulk, strength to the filament yam and to vary its look and feel. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

Claims

WE CLAIM:

1. An apparatus (10) for producing a plurality of distinct yarns comprising: an extruder unit (40) configured to receive polymer from a hopper unit (20) and melt the received polymer by passing the polymers through a plurality of temperature zones; a continuous polymer filtration unit (50) operatively coupled to the extruder unit (40), wherein the continuous polymer filtration unit (50) comprises a plurality of micron candles (60) configured to remove foreign impurities from melted polymer; a spinning packs unit (70) operatively coupled to the continuous polymer filtration unit (50), wherein the spinning packs unit (70) comprises: a metering pump (80) configured to regulate the flow of purified melted polymer; a spinneret chamber (90) operatively coupled to the metering pump (80), wherein the spinneret chamber (90) is configured to produce the plurality of distinct yams from the purified melted polymer using a hydraulic splitting process; a quenching chamber (100) operatively coupled to the spinning packs unit (70), wherein the quenching chamber (100) is configured to solidify a molten filament of the plurality of yarns by an application of cold air; and a texturizing unit (120), wherein the texturizing unit (120) comprises one or more intermingling jets (130) comprising one or more micro holes configured to generate turbulence to the plurality of yarns to produce a plurality of torque-free yams using a false-twisting technique.

2. The apparatus (10) as claimed in claim 1, wherein the hopper (20) comprises a dryer (30) configured to remove moisture from the polymer.

3. The apparatus (10) as claimed in claim 2, wherein the dryer (30) comprises a static mixer configured to enable the mixing of the polymer homogeneously.

4. The apparatus (10) as claimed in claim 1, wherein the extruder unit (40) comprises a plurality of heaters configured to produce the plurality of temperature zones.

5. The apparatus (10) as claimed in claim 1, wherein the metering pump (80) comprises a plurality of precision gears configured to regulate the flow of the purified melted polymer.

6. The apparatus (10) as claimed in claim 1, wherein the texturizing unit (120) is configured to create one or more nips in the plurality of yams using the one or more intermingling jets (130).

7. The apparatus (10) as claimed in claim 7, wherein the one or more intermingling jets (130) comprises 1.1 mm diameter with the one or more nips 16 to 18 per meter.

8. The apparatus (10) as claimed in claim 1, wherein the continuous polymer filtration unit (50), the spinneret packs unit (70), the quenching chamber (100) and the texturizing unit (120) are configured to remove godets from the plurality of produced yarns.

9. The apparatus (10) as claimed in claim 1, further comprising a spin finish applicator (110) operatively coupled to the quenching chamber (100), wherein the spin finish applicator (110) comprises a spray type applicator configured to enable uniform application of spin finish on the plurality of yarns.

10. The apparatus (10) as claimed in claim 1, further comprising a winding unit (140) operatively coupled to the texturizing unit (120), wherein the winding unit (140) is configured to wound the plurality of torque-free yams on a paper tube (150).