JPS599647B2 - Manufacturing method of bulky yarn - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improved method for manufacturing soft bulky yarn packages suitable for pancage dyeing.

Conventionally, it is a well-known technique to subject multifilament yarns to a fluid turbulence treatment to form loops and entanglements to form bulky yarns.

Attempts have also been made to wind up such bulky yarn into a soft package and dye it as is, or to dye it by replacing it with a dyeing tube to create a so-called yarn-dyed yarn.

However, bulky yarn undergoes heat shrinkage during yarn dyeing, and at that time, the bulky yarn in the inner layer of the package is tightened.
It tends to have a dyeability different from that of the bulky yarn of the outer layer.

Furthermore, when the bulky yarn in the inner layer is tightened by heat shrinkage, the loops of adjacent yarns become entangled with each other, resulting in an unwinding tension that is different from that of the bulky yarn in the outer layer when the pancage is unwound, and may result in poor unwinding. This method has the disadvantage that a large amount of tension is applied to the yarn, which tends to cause the weakly entangled portions of the loops to come undone or cause the yarn to break, making processing difficult.

In order to improve these drawbacks, Japanese Patent Application Laid-Open No. 501-9073
A method is disclosed in which a yarn is subjected to fluid turbulence treatment in Step 7, stretched, and then wound into a package under low tension to produce a soft package suitable for dyeing.

However, this method is characterized in that the strength of the loops is improved by stretching the yarn after the fluid turbulence treatment, thereby making the yarn less susceptible to tension fluctuations in subsequent steps.

However, when stretching with this method, the yarn is stretched in areas where the entanglement strength of the loops is weak, and the loops tend to unravel. Since the loop is elongated, the bulkiness is reduced.

Furthermore, in JP-A-50-89659, a multifilament yarn is brought into contact with a heating element under low tension to prevent heat from being uniformly transmitted to all filaments, and then subjected to fluid turbulence treatment without applying substantial tension. A method for producing spun yarn-like filament-processed yarn that exhibits great bulk by winding and heat treatment is disclosed.

The bulky yarn obtained by such a method is characterized in that it has greater bulkiness due to heat treatment than that obtained by simply treating multifilament yarn with fluid turbulence. It only provides a method for producing filament textured yarn, but does not mention a preferred implementation method when used as a yarn-dyed yarn.

Moreover, when the yarn is brought into contact with a heating element under low tension, there is a drawback that yarn breakage is likely to occur if the yarn is run at a large overfeed rate.

The present inventors have addressed these drawbacks of the prior art, particularly in the method of JP-A-50-89659, improving the running stability when running in contact with a heating element, improving the bulkiness of the obtained bulky yarn, and It has a uniform loop in the length direction of the yarn, has a bulk density suitable for replacing with a dyeing tube, and even when package dyeing is performed, there is no difference in dyeing between the inner and outer layers of the yarn-dyed yarn. The present invention was arrived at as a result of intensive studies aimed at providing a method for manufacturing bulky yarn packages without differences in properties or unwinding tension.

That is, the present invention involves (1) bringing a thermoplastic multifilament yarn with a boiling water shrinkage rate (B) of 3% or more into contact with a heating element under low tension so that the heat from the heating element is not uniformly transmitted to the entire filament; After running in contact, (2) supply the fluid to a turbulent region to form loops and entanglements, and (3) when winding, set the overfeed rate of 11 A% in (1) to 4≦A≦15 and uniform. B≦A≦(-B+]22, and the overfeed rate C% in (2) is (20
-A)≦C≦(60-A), and in (3), the winding tension is 0.01'/d or less and the bulk density is 0. 3 0
This is a method for producing a bulky yarn characterized by winding it into a package having a size of @/cc or less.

The yarn obtained by the step (1) above, in which the thermoplastic multifilament is brought into contact with a heating element under low tension so that the heat from the heating element is not uniformly transmitted to all the filaments, is obtained by making individual filaments It is a yarn that has a random heat shrinkage difference in size and cycle and a yarn length difference along the length of the yarn, and has a latent crimp development property in which crimp occurs and bulkiness increases when the yarn is heat treated.

The bulky yarn of the present invention is obtained by treating such yarn with fluid turbulence in step (2) to form loops and entanglements, and then winding it up in step (3). It is a bulky yarn that can increase bulkiness.

Therefore, the feature of the present invention is to specify the boiling water shrinkage rate of the multifilament yarn to be supplied, and to
) and (2), the overfeed ratios (5) and (C) of filament 1, as well as the winding tension and package bulk density in step (3), were set within specific ranges.

That is, when running the thermoplastic multifilament yarn in contact with a heating element in step (1), the boiling water shrinkage rate (B) of the yarn is set to 3% or more, preferably 5% or more, and the overfeed rate ( The essential requirements 22 are that 8 be 4 to 15%, 11 and 1B to (-B+8)%.

If the boiling water shrinkage rate (B) of the filament is less than 3%, the O1 bar feed rate (5) is less than 4%, and/or the filament's boiling water shrinkage rate (B) is less than 4%, the potential shrinkage rate obtained in the step (1) above is The effect of providing random heat shrinkage differences in size and period and yarn length differences along the individual filaments of a multifilament yarn having .

For this reason, the yarn is subsequently treated in the fluid turbulence process described in (2) above to intertwine the crimps and loops of the individual filaments, and the wound yarn has a high bulk, especially due to heat treatment. If the increase is small, the object of the present invention cannot be achieved.

In addition, in the relationship between the boiling water shrinkage rate (B) and the overfeed rate fA) of the thermoplastic multifilament yarn to be supplied, the range of the overfeed rate fA) in which the present invention can be applied is shown as the shaded area in FIG.

On the other hand, if the overfeed rate fA) is increased and the filaments are brought into contact with the heating body, the non-uniformity of the heat transmitted to each filament increases, the difference in thermal shrinkage increases, and the potential shrinkage ability increases.

However, if the overfeed rate (A) is made larger than 15%■ and/or larger than (-B+8)2%, the runnability of the yarn made to run in contact with the heating element deteriorates, resulting in frequent yarn breakage. However, it is not suitable for industrial production.

The multifilament yarn obtained by bringing the filament into contact with the heating element under low tension so that the heat from the heating element is not uniformly transmitted to the filament is then placed in a fluid turbulence region in step (2). It is passed through, formed into loops and tangles, and then wound up.

In the present invention, the overfeed rate (q) when supplying the multifilament to such a fluid turbulence area is expressed as (20-A)
~(.60-A)% is an essential requirement, and (2
It is more preferable to set it as 5-A) - (50-A)%.

If the overfeed rate (q) is less than (20-A)%, the bulk of the final multifilament will be small. Compared to this, the bulk density of the package tends to be high, and if the bulk density is set to a preferable value, the package form deteriorates and the unwinding property from the package deteriorates, which is not preferable.

On the other hand, if it exceeds (60-A)%, the bulky yarn obtained will have many large loops in terms of shape and number.
This is undesirable because the unwinding property from the yarn-dyed package deteriorates, tension fluctuations become thicker, and yarn breakage occurs if the yarn is too loose.

In addition, in relation to the overfeed rate (Q) and the overfeed rate (fc), the range of the overfeed rate (Q) that can be achieved in the present invention is shown as the shaded area in FIG.

Furthermore, the tension when winding the bulky yarn with the winder in step (3), which is a feature of the present invention, is 0.08'? /d or less and the bulk density is 0. 30? /CC or less, the winding tension must be 0.06P/d or less and the bulk density o. It is more preferable to use a package of 27y7cc or less.

If the winding tension is greater than 0.08 P/d, the inner layer of the package will be tightened, so when the dyeing package is unwound, the unwinding tension of the inner layer will be high and the fluctuations will be large, which is not preferable.

Note that the winding tension is expressed as a value obtained by dividing the average value of tension measurements immediately after the traverse fulcrum by the bulky yarn denier after winding.

The bulk density of the rolled up package is 0. 30? /c
If it is larger than c, it will be difficult to remove the soil rolling tube from the pan cage when replacing it with the dyeing tube.
Further, when dyeing the pan cage as it is, it becomes difficult for the dye solution to circulate uniformly within the pan cage, and a difference in dyeing tends to occur between the inner layer and the outer layer of the pan cage.

In addition, when winding up the bulky yarn, it is also possible to adopt a method in which the bulky yarn is directly wound onto a dyeing tube and then the tube is dyed.

Next, the method of the present invention will be explained with reference to FIG.

A thermoplastic multifilament yarn 1 is fed to a roller 3 via a tensor 2 that suppresses fluctuations in unwinding tension.

4 is a heating pin, and the thread is over 7 between rollers 3 and 5.
The heating pin 224 is caused to run in contact with the heating pin 224 with an eid rate A of 4% or more and 15% or less, or 11-B% or more (-B+8)% or less.

In this case, the thread runs in contact with the heating pin in a low tension state, and the tension at this time is preferably 5 to 60 m9/d.

The temperature of the heating pin 4 needs to be above the secondary transition point and below the melting point of the supplied yarn, preferably above the temperature at which the thermal shrinkage stress of the yarn becomes maximum.

Next, the yarn is fed to the fluid turbulence nozzle 7 with an overfeed rate (Q of (20-A)% or more and (60-A)% or less) between rollers 5 and 8 to form loops and entanglements, and then the yarn is sent to the winder. In step 9, the winding tension is set to 0.08?/d or less, and the product is wound into a pan cage having a bulk density of 0.30?/CC or less.

It should be noted that if moisture is added to the yarn by the moisture adding device 6 before the treatment by the fluid turbulence nozzle 7, the effect of the fluid turbulence treatment will be improved.
This is more preferable because the strength of the loops is increased and the uniformity of the loops and entanglements in the length direction of the filament is improved.

Note that FIG. 3 shows a preferred example of the present invention, and the present invention is not limited thereto. The yarn treated with is wound up once and then treated with a fluid turbulence nozzle, and the heating pin and the rollers before and after the fluid turbulence nozzle each give a difference in circumferential speed in order to take the relaxation rate. As a method, a method such as using a large diameter portion and a small diameter portion of one stepped roller can be adopted.

The thermoplastic multifilament yarn that can be used in the present invention may be any thermoplastic polymer that is a homopolymer or a copolymer such as polyamide, polyester, polyacrylic, polyolefin, or the like.

In addition, known pigments, antistatic agents,
Even if it contains a small amount of flame retardant etc., it does not substantially impede the effects of the present invention.

The cross-sectional shape of the filament may be either a round cross-section or an irregular cross-section, and since a fine denier and a large number of filaments improve the entanglement strength of the loop, the single filament denier is preferably 3.2 d or less, and 2.1 d or less. is particularly preferred.

Furthermore, the total number of filaments is preferably 20 or more《, 24
It is particularly preferable that the number is more than 100 yen.

The bulky yarn obtained by the present invention has a bulky value of 18CC/P after heat treatment, which is obtained by the bulky height measurement method described below.
As mentioned above, the preferable value is 20CC/f? It is preferably 5 cc/f or more higher than the bulkiness value without heat treatment.

The effects of the method of the present invention are summarized as follows.

■ Effect of random heat treatment a. The bulky yarn obtained by the present invention differs from the bulky yarn obtained by simply subjecting it to fluid turbulence treatment, and has a latent shrinkage ability, and its bulkiness is increased by heat treatment.

In other words, when a bulky yarn that has been simply subjected to fluid turbulence treatment is dyed into a soft pancage, the bulkiness of the yarn is significantly reduced; Even when yarn is package dyed, its bulk decreases only slightly, or rather tends to increase.

Furthermore, since the bulky yarn does not use up all of its shrinkage ability during dyeing, the bulkiness is further improved if heat treatment is performed after the dyed yarn is made into a knitted fabric.

Therefore, a knitted fabric made from yarn-dyed yarn obtained by dyeing a bulky yarn package according to the method of the present invention has a higher bulk than a yarn that has been simply treated with fluid turbulence and is subjected to the same yarn dyeing process and made into a knitted fabric. The result is a fabric with a good texture.

b. Compared to a method in which elongation is performed after fluid turbulence treatment, a bulky yarn having uniform loops in the length direction of the yarn can be obtained.

C. Heat treatment reduces the thermal shrinkage rate of bulky yarn, so it is possible to reduce the shrinkage of bulky yarn during pancake dyeing, preventing differences in dyeing, quality, and unwinding tension between the inner and outer layers of the package. can do.

Furthermore, since the innermost layer of the pancage is not plated excessively, the amount of waste yarn that has conventionally been produced can be reduced.

■ Effects of setting the overfeed rate and the heat shrinkage rate (B) of the supplied filament yarn within a specific range in random heat treatment a. Great bulkiness and running stability can be satisfied at the same time.

■ Effects of setting the overfeed line q within a specific range in fluid turbulence processing a. Good package form, great bulk and
Good unwinding properties from the yarn-dyed package can be satisfied at the same time.

■ Effects of rolling up the package a. When replacing the rolled up package with the dyeing tube, the replacement becomes easy.

b. During dyeing, the dye solution circulates uniformly within the package, allowing the package to be dyed uniformly.

The methods for measuring the bulk density, bulk height (without heat treatment, after heat treatment), overfeed rate (Q), and overfeed rate (Q) of the pan cage are described below.

(Bulk density of package) The volume of yarn wound around the package (CC) is the weight of yarn (1
) is displayed.

(Bulk height after heat treatment) Figure 4 shows a sketch of the bulk height measurement device, and Figure 5 A, B, and C.
A sketch for explaining the measurement method using the measurement device is shown in FIG.

Two notches 15 are provided on the top surface of the sample stage 10, the distance 16 between the outer edges thereof is 6 mm, and the notches 15 have a width of 2 mm. Spread a 5 cm flexible thin cloth tape 11,
A metal fitting 12 with a pointer and a load 13 are connected to its lower end.

The metal fitting 120 pointer has a scale of 140 when no sample is attached.
Z to indicate 0th place.

The sample is 1m long. One skein is made by winding 80 times using a skein removal machine, and 2 to 10 skeins are prepared depending on the indicated fineness, and each skein is hung separately in air at 200±2℃ for 5 minutes without a load. Heat treatment is performed, and the heat-treated cold is adjusted so that the indicated fineness is 48,000 denier (for example, 30
If it is a denier thread, 3 0 x 80 x 2 = 4 800
, 48000 ÷ 4800 = IO, 10 winds, 75 denier yarn, 75 x 80 x 2 = 12000, 480
00÷12000=4 (4 skeins)) Align them in parallel.

Next, this set of winds is the fifth one. Fold in four as shown in A to form sample 17, and fold this into four as shown in FIG.
As shown in the front view of C and the cross-sectional view of C,
1. Insert it between the specimen stage 10 and the sample stage 10.

The load 13 is combined with the metal fitting with a pointer to become 501, and the value L (cx) indicated by the pointer is read.

The measurement sample 11 is measured three times in total by moving the position, and the average value L (crn) is determined.

The bulk height M is calculated from the following formula.

Volume in tape V M (CC/P) = = - weight of yarn in tape W ([)2 V = - X 2. 5 π 100 1 W=DX XPX0.025X-100-
SH 9000 Here, D is the fineness (denier) of the sample yarn before heat treatment, and P is the number of parallel yarns in the tape.

In addition, SH is the shrinkage rate during dry heat treatment, and the cold used for bulk height measurement is 4r/l9/
This is a value obtained by measuring with a load corresponding to d and expressed as a percentage.

(Bulk height without heat treatment) In the bulk height measurement method after heat treatment, the same operations and calculations are performed except that the heat treatment operation at 200° C. is omitted and SH=0 in the calculation formula.

(Overfeed rate A) If the surface speeds of the roller feeding the yarn to the heating element and the roller taking it out are V1 and V2rrL/m, respectively, V1-v
2 Overfeed rate A% = -X 1 0 0 and V
2 Find it.

(Overfeed rate C) When the surface speeds of the roller feeding the yarn into the fluid turbulence area and the roller taking it out are v3, V, and rIL/miyr, respectively, V3-V, the overfeed rate is determined as C%1×V4 100.

The present invention will be specifically explained below with reference to Examples.

Example 1 Using the apparatus shown in FIG. 3, a drawn polyethylene terephthanate yarn 150D-72 having a boiling water shrinkage rate (B) of 12% was processed.

In this case, the circumferential speeds of rollers 3 and 5 are 220 and 2, respectively.
0 0 m. / mvt (the overfeed between o-lars 3 and 50 is 10%), a heating pin 4 with an outer diameter of 35 rIrft was used at 215 °C, and water was applied at a rate of 5 cc/min from the water supply device 6 to the thread. granted to.

As the fluid turbulence nozzle 7, the nozzle described in US Pat. No. 3,545,057 is used, and the flow rate is 6 N F7L.
'/hr, pressure 5 k9/cni, and the circumferential speed of roller 8 was set to 154rrL/R (roller 5
, 8 (Q is 30%) and the winding tension is 0.04f? /d and roll width 15 for cheese with outer diameter 80mw
1kg was wound up with 06rfL.

The bulk density of the wound package is 0. 2 2′? /
cc, the fineness of the bulky yarn is 188D, and the bulk height is 16ec/
f? The bulk level after heat treatment is 24CC/? , boiling water shrinkage rate is 5
%Met.

The package was replaced with a dyeing tube with an outer diameter of 75 mm and dyed using a conventional yarn dyeing method as described in JP-A-50-90737. I re-oiled the cone with Corning oil and assembled it.

Is the bulk height of yarn dyed packaged yarn 17CC/f? , the bulk height after heat treatment is 20CC/f? The difference in dyeing between the inner and outer layers, the difference in yarn quality, and the difference in unwinding tension before winding the cone were of no practical problem, and the amount of yarn waste was as small as 0.5%.

The yarn-dyed yarn wound back into a cone was then knitted and finished, and the resulting knitted yarn had excellent texture and quality, and exhibited extremely high bulk.

Comparative Example l Polyethylene terephthalate drawn yarn 150D-72F with a boiling water shrinkage rate (B) of 12% and 5% was prepared without using the roller 3 and the heating pin 4 (i.e., without using the step (1) of the present invention). The process was carried out in the same manner as in Example 1, except that the sample was supplied to roller 5.

Table 1 shows the properties of the obtained package and bulky yarn.

Next, each package was yarn-dyed, cone-rolled, knitted, and finished into a knitted fabric in the same manner as in Example 1. The evaluation results for each process are also listed in Table 1.

Example 2 150 with various boiling water shrinkage ratios (B) shown in Table 2
-72 polyethylene terephthalate drawn yarn was supplied to the apparatus shown in FIG. 3, and processed in the same manner as in Example 1, except that the circumferential speed of the roller 3 was changed and the overfeed rate was set as shown in Table 2.

Table 2 shows the quality and workability of the obtained bulky yarn.

In addition, in Table 2, Experiment A61, 2, 4, 5, 8, 9, 12,
Examples 13, 16, 17, and 19 are comparative examples for clarifying the effects of the present invention.

In Experiment/16.1, the boiling water shrinkage rate (B) of the supplied yarn was as low as 2%, so the bulkiness (without heat treatment) was low, and the increase in bulkiness due to heat treatment was also small.

Experimental rots 2, 5, 9, 13 and 17 had low overfeed rates and lacked bulk as in Experiment/16.1.

In addition, in experiments Ai: 4, 8, 12, 16 and 19, the overfeed rate was large, so running properties deteriorated in the process of running in contact with the heating pin, and yarn breakage occurred.

Example 3 A drawn polyethylene terephthanate yarn of 150D-72F having a boiling water shrinkage B) of 10% was overfeeded using the apparatus shown in FIG. 3 by changing the circumferential speed of roller 3 and roller 80 as shown in Table 3. The fabrics A and C were processed in the same manner as in Example 1, and yarn dyeing and cone rewinding were performed.

The quality of the obtained bulky yarn and the unwinding property upon unwinding the cone from the yarn-dyed package are shown in Table 3.

In Table 3, experimental plates 20, 24, 25, 29, 30, and 34 are comparative examples for clarifying the effects of the present invention, and the overfeed rate C was reduced (experiment A20).
, 25, 30) are all inferior in bulk, and the overfeed rate C is set to a thick level (Experiments 24, 29, 34).
In all cases, the unwinding tension when winding the yarn-dyed package back onto the cone became higher and more variable toward the inner layer, resulting in frequent thread breakage.

Example 4 The circumferential speed of the roller 8 in Example 1 was set to 143 m/mi.
Overfeed rate between YTC rollers 5 and 8 (q is 4
0%), and the winding tension is 0.05, 0.07, 0.08.
, 0.09 g/d, but was processed in the same manner as in Example 1, including yarn dyeing, cone winding, knitting, and finishing.

1 Table 4 shows the characteristics of the obtained bulky yarn and package, and the evaluation results in each process.

Experiment A38 was a comparative example to clarify the effect of the present invention, and the unwinding property from the yarn-dyed package was poor due to the high winding tension.The part where the loops were stretched entered the knitted fabric and the quality was also poor. .

Example 5 The peripheral speed of the roller 80 in Example 1 was set to 167 rn/m.
in (overfeed rate between rollers 5 and 8 (Q is 2
0%) and the winding tension is 0.05, 0.06, 0.07f.
The fabric was processed in the same manner as in Example 1 except that /d was used, and yarn dyeing, cone winding, knitting, and finishing were performed.

Table 5 shows the characteristics of the obtained bulky yarn and package, and the evaluation results in each step.

Experimental laundry 41 is a comparative example for clarifying the effect of the present invention, and the bulk density of the wound yarn is O-31? /cc and high《Since it was not possible to pull out the yarn layer from the package, it was directly rolled up into a dyeing tube and pre-dyed, so there was a difference in dyeing between the inner and outer layers of the pancage, and even in knitted fabrics, dyeing spots degraded the quality. was.

[Brief explanation of the drawing]

Figure 1 shows the relationship between the boiling water shrinkage rate (B) and overfeed rate of the supplied thermoplastic multifilament yarn, and Figure 2 shows the relationship between overfeed mA) and overfeed rate (C). FIG. 3 is a schematic diagram showing a preferred embodiment of the present invention, FIG. 4 is a schematic diagram of a bulk height measuring device, and FIG. 5 is a schematic diagram for explaining the bulk height measuring method. 1: Thermoplastic multifilament yarn, 3, 5, 8: Roller, 4: Heating pin, 6: Moisture imparting device, 7: Fluid turbulence nozzle, 9: Winder, 10: Sample stage, 11: Thin cloth tape , 13: Load, 14: Scale, 17: Sample.

Claims (1)

[Claims] 1 A thermoplastic multifilament yarn having a boiling water shrinkage rate (B) of 3% or more is (1) brought into contact with a heating element under low tension so that the heat from the heating element is uniformly transmitted to the entire filament. After (2) supplying the fluid to the turbulent region to form loops and entanglements, {3} when winding, the overfeed rate A% in h) should be 4≦A11≦15 and 1B≦A≦(-B+8), and 2 in (2)
2, the overfeed rate C% is (20-A)≦C≦(
60-A), and the winding tension in (3) is 0.08P.
A method for producing a bulky yarn, comprising winding the yarn into a package having a bulk density of 0.30 g/cc or less and a bulk density of 0.30 g/cc or less.