JPS6111325B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for producing a three-dimensional curl filament, and particularly to an improved method and apparatus for producing a three-dimensional curl filament made of synthetic fibers used as a raw material for locking material for cushioning materials. be.

Conventionally, filaments have usually been bidirectional, so even if the intersections of the filaments are bonded with an adhesive, there has not been much increase in rebound or improvement in cushioning properties. Further, when attempting to form a three-dimensional curl, the curl is mainly formed only around a part of the core, so that the desired three-dimensional curl cannot be formed. Furthermore, with conventional curl forming devices that perform false twisting, the maximum total denier is mechanically limited to 2000 denier, and therefore only small curls can be formed.

In order to improve these drawbacks of the conventional equipment, we have developed a system that is equipped with a heating device using moist heat just before processing, and a false twisting device for two consecutive rope twists: the first normal twist and the second round twist. In the meantime, a strong heating device is installed to heat set the large and small double spiral crimp on the thermoplastic filament, and then the false twist is removed and the continuous single thread is cut into a thick several hundred deniers by the cutting device. A continuous manufacturing device for synthetic fiber crimped staples for cushion materials has been proposed (Public Act No. 49-40402).
Publication No.). However, this device has a drawback in that it does not have sufficient effect on the product by preventing the rough twisting in the second twisting step from spreading to the first ordinary twisting step.

In order to eliminate such conventional drawbacks, the present inventor first developed a tension driving means and a plurality of single-stranded strands provided in front of the tension driving means and tensioned and transported by the tension driving means. a guide roller having a group of U-shaped grooves that rotates so as to exert opposite effects on the filament at the front and rear; a pair of rotating grooved rollers provided in front of said group of rollers with non-slip means for pulling said double-twisted filament at a transport speed and distance sufficient to form a twist and complete heat setting; a heating means for the filament in which the double twist has been formed; and a group of plural single-twist transfer rollers provided in front of the heating means and provided with a required rotational tension to form the single-twist and guide the filament. We have discovered a device comprising: and means for stopping the spread of double twisting provided on the rearmost roller of the roller group (Japanese Patent Application Laid-Open No. 144448/1983). however,
When a presser roller is used as a means to stop the spread of double twist, a strong pressing force is applied to the double twist of the filament, which not only makes untwisting and opening difficult due to thermal deformation, but also causes plastic deformation. The deformation causes the filament to deform, resulting in poor cushioning properties and weakening of the filament.

Therefore, the object of the present invention is to create a three-dimensional curl, that is, a three-dimensional curl, which, when made into a locking material and incorporated into a cushioning material, makes the greatest contribution to increasing the rebound elastic force and improving the cushioning properties. An object of the present invention is to provide a method for producing a three-dimensional curl filament and an apparatus therefor, which can impart a three-dimensional curl to a fiber filament.

Another object of the present invention is to provide a method and apparatus for producing a three-dimensional curl filament in which the double twist formed in the double twisting process does not affect the single twisting process.

For these purposes, the diameter at the bottom of the groove is 10~
A plurality of rollers are provided between the first free roller with a groove of 500 mm and at least one other second free roller.
Total denier of thick denier filament
50,000 to 3,000,000, and forming a single twist in the filament by applying twisting force in the subsequent double twisting step, and forming a double twist in the filament from the starting point after passing through the single twisting step. A double-twisting step in which the double-twisted filament is heated by passing it through a cylindrical guide means, and the formed double-twisted filament is cooled while applying a twisting force to give the filament a double twist. a cooling process to complete the heat setting; an untwisting process to untwist the heat-set double-twisted filament to form a three-dimensional curl filament; and a cutting process to cut the untwisted three-dimensional curl filament. This is achieved by a method for producing three-dimensional curl filaments, which includes a cutting process.

The method includes a means for cutting untwisted filaments, a tension driving means, and a plurality of single twisted filaments provided in front of the tension driving means and being tensioned and transported by the tension driving means. and a group of guide rollers having a group of U-shaped grooves that rotate so as to give opposite effects to each other at the rear, and a filament provided immediately after the frontmost roller of the roller group to form a double twist. a pair of rotating grooved rollers with non-slip means for pulling the double-twisted filament at a transport speed and distance sufficient to complete heat setting; A cylindrical guide means for the twisted filament, a heating means for the double-twisted filament to be formed, a grooved free roller provided in front of the guide means and having a diameter of 10 to 500 mm at the groove bottom, and others. This is achieved by a three-dimensional curl filament manufacturing apparatus comprising at least one free roller and a single twisting means for forming a single twist in the filament by the twisting force in the double twisting step.

The filaments used in the present invention are preferably synthetic fibers and natural fibers such as polyester, polyamide, polypropylene, polyacrylonitrile, polyvinylidene chloride, vinylon, etc., among which polyester fibers are most preferred. In other words, polyester filament has better rigidity and greater repulsion than other synthetic fibers, and as will be described later, when used in the form of a locking material for a cushioning material, an extremely good cushioning material can be obtained. It is. Therefore, the filaments used in the present invention have a monofilament of 50 to 3000 denier, preferably 100 to 1000 denier, most preferably 150 to 600 denier, and a total denier of 50000 to 3000000 denier, preferably
100000-2000000 denier, most preferably
It is 150,000 to 1,000,000 denier.

The three-dimensional curl filament obtained by the present invention can be incorporated into a cushioning material alone after cotton manufacturing to improve cushioning properties and rigidity, or can be locked into a predetermined shape by bonding the intersections of the filament with an adhesive. This forms a locking material, which can be used alone as a cushioning material or incorporated into another cushioning material to improve cushioning properties and rigidity.

Next, the present invention will be explained in detail with reference to the drawings. As shown in FIGS. 1 to 5, a filament supply port 1, a group of single twist transfer rollers 2, a heating means-equipped guiding means 6, a twisting device 4, and a tension driving means 5 are arranged in the order of the filament feeding direction. Next, each device will be explained in detail.

A plurality of filaments F, which are almost uniformly bundled at the filament supply port 1, are stretched over rollers 2 for a single twisting process. The rollers 2 include a first roller 2a with a groove and which can rotate freely, and at least one other second roller 2b which can rotate freely.
It becomes more. Although it is desirable that the second roller 2b has a groove, it is not necessarily necessary to provide the groove. If necessary, other rollers may be provided in addition to the second roller 2b, but as shown in FIG. 1 and FIG. They may be provided coaxially instead of the rollers, and it is usually desirable to provide three to four or more on each roller. The coaxial rollers must each have the same diameter. Therefore, the filament F has a double twist Fd formed in a double twist process as described below, as shown in FIG.
As shown in FIGS. 3 and 5, the single strand Fs is stretched over the first grooved roller 2a, then the single twist Fs is stretched over the second roller 2b, and then the first and second rollers 2a, 2b. Each roller is placed coaxially with the rollers in turn, and finally the
The filament F is set to be connected to the filament supply port 1.

In this case, the diameter D at the groove bottom of the grooved first roller 2a is 10 to 500 mm, depending on the total denier of the filament used, the angle θ between the double-twist Fd part and the single-twist Fs part, etc. It is preferably 20 to 300 mm, most preferably 30 to 150 mm. Also, as shown in Figure 4, the angle θ between the double-twisted Fd part and the single-twisted Fs part is
The angle is preferably 90° or less, particularly 0 to 85°, most preferably 20 to 70°. Although productivity increases by increasing the filament feeding speed, it is necessary to increase the size of the heating means and cooling means accordingly.
Further, the width of the grooved first roller 2a is desirably slightly wider than the diameter of the double strand so that the formed double strand is not further twisted to form a triple or more strand. Note that instead of the groove, two plates having the above-mentioned widths may be attached to the grooveless roller perpendicularly to its axis. In addition, when a plurality of rollers are provided coaxially on the first and second rollers 2a and 2b, the grooves of one roller are connected to the grooves of the opposing roller, as shown in FIG. It is desirable to have it between the two. Further, a guide 38 may be provided between the grooves.

The guide means 3 equipped with a heating means includes a pipe 3a through which the double-twisted filament Fd is passed;
It consists of a jacket 3b outside the pipe 3a, a pipe 3c for introducing high-pressure steam into the jacket 3b, and a pipe 3d for discharging it. However, pipe 3a
Similarly to the groove width of the first roller 2a, the inner diameter of
It is desirable that the diameter of the double strand is slightly larger than the diameter of the double strand so that the formed double strand is not twisted further. Further, it is desirable that the distance between the guide means and the first roller 2a be as small as possible so that the double twist is not further twisted. Similarly, it is desirable that the distance between the twisting device 4 and the guide means 3, which will be described later, be as small as possible. In addition to this, the heating means may be electric heating, infrared rays, high frequency heating, or the like. Further, in order to improve efficiency, the heating means may be provided to heat not only the guide means but also the entire single twisting process consisting of the rollers 2a and 2b, as shown in FIG. In this case, the heating portion of the guide means 3 can be made smaller and may be omitted in some cases.

The twisting device 4 has two rotary disks 6 and 7 connected by a plurality of arms 8 and 9, and tubular shafts 10 and 11 are horizontally installed in the centers of the rotary disks 6 and 7. The tubular shafts 10, 11 are supported by bearings 12, 13, respectively. A hollow shaft 14 into which the filament is introduced is rotatably fitted inside the tubular shaft 10 on the filament introduction side. The diameter of this hollow shaft is also desirably slightly larger than the diameter of the double twist. Spur gears 15 and 16 are fixed to the ends of the tubular shaft 10 and the hollow shaft 11, respectively. Below each spur gear 15, 16 is a spur gear 17 coaxially fixed to the shaft 32,
18 are provided respectively, forming a series of combination gears T. A sun gear 19 is attached to the other end of the hollow shaft 14 protruding inward from the disk 6, and planetary gears 20 and 21 are attached around the sun gear 19, respectively.
A grooved rotary roller 22, 23 is connected to these planetary gears 20, 21 via fixed shafts 24, 25, respectively. These grooved rotary rollers 22 and 23 are provided with corrugations so that the filament having a double twist can be pulled without slipping. Further, the number of grooves is determined to ensure a necessary length to maintain a cooling distance, and the tip of the fixed shaft 24 and the tip of the fixed shaft 25 are connected by a bracket 26. Guide rollers 27 and 30 are attached to the center of the bracket 26 via brackets 33 and 34 on both sides thereof. Arm 8 has
Guide rollers 28 and 29 are attached to the U, which rotates so as to give opposite twisting effects to the plurality of filaments being transported at the front and rear sides.
A guide roller group R having a letter-shaped groove is formed. Further, a drive pulley 31 is fixed to the tip of the tubular shaft 11, and the pulley 31 is connected to the belt 3.
5 is connected to a pulley 37 connected to a power source 36. It goes without saying that sprockets and chains can be used in place of the pulleys 31, 37 and belt 35.

As the tension driving means 5, there are rollers etc.
Further, a cutting device may be provided after that, but the first
It is desirable to provide a rotary cutter with a cutting device, as shown in Figures 2 and 6. This rotary cutter 5 is a rotor spa〓〓〓〓
The rotor spider 39 is made up of a rotor disk 40 and a rotor ring 41 via a spider 39. Knives 42 are inserted into the grooves, and knife retainers 43 are erected radially on the rotor ring 41. The knife retainer 43 is confined to the rotor disk 40 by bolts 44. A hopper 45 is provided at the bottom of the rotor ring 41. The shaft of the rotary cutter is connected to a transmission 47 by a coupling 46, and further connected to a torque motor 48.
connected to. Further, a presser roller 50 is fitted into a groove 49 formed between the rotor disk 40 and the rotor ring 41. This presser roller 50 is attached to the frame 5 by a swing arm 51.
2, and the gap between the blade and the cutting edge of the knife 42 is adjusted by swinging the swing arm. The swing arm 51 is swung by attaching a handle 53 to a socket 55 and rotating a screw 54, and is pushed toward the knife 42. This allows the untwisted filament to be pulled and cut at the same time.

Next, a method for producing a three-dimensional curl filament using the above-mentioned apparatus will be explained.

A plurality of filaments F, for example, synthetic fiber filaments, are pulled out from a plurality of bobbins (not shown), passed through the filament supply port 1, and applied to the first and third rollers 2a and 2b of the single-twist transfer roller group 2.
and as shown in FIG.
It is passed through the tubular shaft 11 and passed through the tension drive means 5.

Next, the motor 36 is driven to rotate the pulley 31 in the clockwise direction. Then, the rotary plates 6, 7 rotate clockwise, and as a result, the tubular shaft 10 fixed to the rotary plate 6 and the gear 15 coaxially fixed to the shaft rotate clockwise. gear 15
The gear 17 meshing with rotates counterclockwise,
Similarly, since the gear 18 also rotates in the same direction as the gear 17, the gear 16 and the sun gear 19 fixed thereto also rotate clockwise like the rotating disk 6, but at different rotational speeds. By rotating the sun gear 19, the planet gears 20 and 21 rotate in the opposite direction to the sun gear. Therefore, opposite twisting effects occur on the plurality of filaments F before and after the U-shaped guide roller group R. That is, when the passage is pulled out through the U-shaped passage formed by the rollers 23, 28, 29, and 30 while applying a rotational twisting force, the twisting force is applied at the first bending angle (roller 27), and the double twist is created. It spreads to roller 2a,
The fourth curved corner (roller 30) serves as a fulcrum for untwisting, producing the effect of untwisting after twisting. Here, the force to send the fibers in the traveling direction is determined by changing the rotational speed of the gear 16 by the combination of the gears 17 and 18 while the rotating disks 6 and 7 and the front gear 15 rotate at the same time (the rotational speed difference between the rotating disk and the front gear 15 is changed). ) to send the strands. Therefore, the total denier of the filament and the occurrence of uniform double twist due to twisting and feeding are adjusted by the ratio of feed and rotation.

On the other hand, the twisting force applied by the roller R gives the filament a double twist as shown in FIG. 8, but although the double twist Fd that is formed reaches the first roller 2a, ,2b
Partial twisting force is applied to the filaments without affecting the filaments stretched between them to make the filaments into a single twist Fs. The roller 2a has such an effect of preventing the spread of double twist only when the diameter of the roller 2a is within the above range. That is, if the diameter is less than 10mm, 50000~
The diameter is too small for the size of the double twist formed by the total denier of 3000000, so
On the other hand, if the pressing force is insufficient and exceeds 500 mm, the influence of the opposing tension becomes small and the roller 2
This is thought to be because the pressing force applied to a is dispersed. In addition, the reason why the filament is wound 2 to 4 times back and forth around the rollers 2a and 2b is because when the filament F is double-twisted, the length becomes about one-fourth of that of an untwisted filament. Resistance is created between the filament and the roller between 2a and 2b, and the twisting stress produces a preventive effect here, preventing the double twist from spreading beyond this point.

The filament with the double twist formed is heated while being guided by the guide means 3 so that the double twist is not further twisted, and is further cooled at the roller group R to complete the heat setting.

Next, at the rear by rollers 30, the fillet
The twisting action acts in the opposite direction between the rotary cutter 5 driven by the torque motor 48, especially the swing roller 50, and the double twist is untwisted and transferred. At the same time, the swing roller 50 presses the knife 42 to a predetermined length, for example, 30 to 300 mm.
In particular, a staple fiber having a three-dimensional curl filament as shown in FIG. 9 is obtained by cutting the fiber into a length of 50 to 150 mm. Note that the torque motor 48 is connected to a power source via a transformer (not shown).

In this manner, the rotary cutter used in the present invention serves as one fulcrum for untwisting the double twist, and thus acts as a cutting means while applying the tension necessary for untwisting to the filament. On the other hand, in the above device, not only does the traveling speed of the filament change depending on the degree of twisting, but also the untwisted filament has curls, so it cannot be cut to size unless it is constantly pulled with an appropriate tension. Have difficulty. However, since the rotary cutter is driven by a torque motor,
Appropriate tension is always applied to the filament, making it possible to cut to size. Therefore, difficulty in untwisting due to loosening between the supports, curling due to too strong tension, and overloading of the motor, which tend to occur when using a normal motor, are eliminated.

Example 1 A polyester filament of 300 denier was used as a monofilament, and the total denier was 500,000 denier. Grooved rotary free rollers 2a and 2b with a diameter of 80 mm at the groove bottom were arranged so that the angle θ between the double strand part and the single strand part was 500,000 denier. The filament was installed at an angle of 45° and stretched as shown in Figure 3, and the filament was fed at a speed of 3.4 m/min and the rotation speed of the roller 2a was 13 r.
The apparatus shown in Figs. 1 and 2 was operated at p.m.
When heat setting was carried out at 120 to 130°C, no spread of the double twist at the roller 2a portion was observed. Further, when the untwisted filament was cut into a length of 80 mm using the rotary cutter 5 driven by the 30 Kg/cm ² torque motor 48, cutting to size was performed.

Example 2 In the method of Example 1, the diameter of the rotating roller 2a was 40 mm, the total denier was 250,000 denier, and the rotation speed of the roller was 16 r.p.m.
When the same method was carried out except that the filament feeding speed was changed to 2.25 m/min, no spread of the double twist in the roller 2a portion was observed at all. Further, when the untwisted filament was cut into a length of 70 mm using a rotary cutter driven by a 30 Kg/cm ² torque motor, cutting to size was performed.

[Brief explanation of the drawing]

1 is a perspective view of the device according to the invention, FIG. 2 is a sectional view of the device according to the invention, FIG. 3 is an enlarged perspective view of the single twisting means, and FIG. 4 is a sectional view taken along the - line in FIG. 3. , FIG. 5 is a cross-sectional view along the V-V line, and FIG.
The figure is a sectional view of a rotary cutter, FIG. 7 is a sectional view showing another embodiment of the heating means, FIG. 8 is a perspective view of a filament with double twist, and FIG. 9 is a three-dimensional view. FIG. 3 is a perspective view of a curl filament. 1...Filament supply port, 2, 2a, 2b...
...single twist transfer roller, 3, 3a...guiding means,
4... Twisting device, 5... Tension driving means and cutting means, 6, 7... Rotating disk, 10, 11... Tubular shaft, 14... Hollow shaft, 15, 16, 17, 18...
... Spur gear, 19 ... Sun gear, 20, 21 ... Planetary gear, 22, 23 ... Grooved rotating roller, 2
7, 28, 29, 30...Guide roller, 31, 3
7...Pulley, 36...Motor, 40...Rotary disk, 41...Rotary ring, 42
...Knife, 45...Hopper, 50...Lola. 〓〓〓〓

Claims (1)

[Claims] 1. A plurality of thick denier filaments with a total denier of 50,000 are placed between a grooved first free roller having a diameter of 10 to 500 mm at the groove bottom and at least one other second free roller. A single twisting process in which the filament is stretched with ~3,000,000 denier and then formed into a single twist by the twisting force in the double twisting process, and a double twist is formed in the filament from the starting point after passing through the single twisting process. A double-twisting step in which the double-twisted filament is heated by passing it through a cylindrical guide means, and the formed double-twisted filament is cooled while applying a twisting force to give the filament a double twist. a cooling process to complete the heat setting;
A method for producing a three-dimensional curl filament, which comprises an untwisting step of untwisting the double-twisted filament heat set in this way to form a three-dimensional curl filament, and a cutting step of cutting the untwisted three-dimensional curl filament. 2. The method according to claim 1, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 90° C. or less. 3. The method according to claim 1, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 0 to 85 degrees. 4 Filament is 50~ as monofilament
3000 denier. A method according to any one of claims 1 to 3. 5. The method according to any one of claims 1 to 4, wherein the cutting step is performed by a rotary cutter driven by a torque motor. 6. A cutting means for untwisted filaments, a tension driving means, and a plurality of single twisted filaments provided in front of the tension driving means and being tensioned and transported by the tension driving means. A guide roller group having a group of U-shaped grooves that rotates to give the action of a rotating grooved roller provided with non-slip means for pulling the double strand formed filament at a transport speed and distance sufficient for the formation of the double strand; A cylindrical guide means for the filament, a heating means for the double-twisted filament to be formed, and a diameter at the bottom of the groove provided in front of the guide means.
A solid body consisting of a first free roller with a groove of 10 to 500 mm and at least one other second free roller, and serving as a single twisting means for forming a single twist in the filament by the heating force in the double twisting step. Curl filament manufacturing equipment. 7. The apparatus according to claim 6, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 90 degrees or less. 〓〓〓〓
8. The apparatus according to claim 6, wherein the first and second rollers are arranged so that the angle between the double twist and the single twist to be formed is 0 to 85 degrees. 9. The device according to any one of claims 6 to 8, wherein the first roller has a diameter of 20 to 300 mm. 10 Filament is 50 as monofilament
9. A device according to any one of claims 6 to 9, which has a denier of ~3000 denier. 11. The device according to any one of claims 6 to 10, wherein the untwisted filament cutting means and the tension drive means are rotary cutters driven by a torque motor. 12. A device according to any one of claims 6 to 11, comprising a single twisting means and two free rollers each having a plurality of grooves of the same diameter.