Plastic and nonmetallic article shaping or treating: processes – With twining – plying – braiding – or textile fabric formation
Reexamination Certificate
2003-09-03
2004-08-24
Edwards, N. (Department: 1774)
Plastic and nonmetallic article shaping or treating: processes
With twining, plying, braiding, or textile fabric formation
C264S169000, C264S211140, C264S210800, C428S364000, C428S395000
Reexamination Certificate
active
06780358
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a manufacturing method for polyester yarn having high denier in monofilament, particularly to a manufacturing method for polyester yarn excellent in yarn transferring, packaging and loosing with no white powder occurred when weaving and polyester yarn made from the same.
PRIOR ART AND PROBLEMS TO BE SOLVED BY THE INVENTION
Polyester fiber is mostly used among three major synthetic fiber owing to its good mechanical features, dyeability and low cost. In the recent, demands in cost down, more rigid material such as shoe sewing thread made from polyester yarn is highly desired accompanied with application of high grade shoe materials to instead polyamide yarn. To meet the requirement, polyester yarn having high denier in monofilament is becoming important. Manufacturing process of polyester filament is approximately as follows: polycondensation reaction of terephthalic acid and ethylene glycol to form polyester chip or melt mass, after melting, extrusion, measuring and throughput, then quenching, oil finishing and winding up. While in this process, the quenching effect of the polyester yarn having high denier in monofilament throughput after melt extrusion is very difficult to control, even in the requirement of equipment and the setting of manufacturing condition. This is a long-felt unsolved problem to the person skilled in polyester manufacturing art.
Spin drawing process is familiar to the person skilled in the synthetic yarn manufacture. The polyester yarn having high denier in monofilament is made in the spin drawing process by direct manufacture of monofilament yarn or combining multi-tow of filaments, then splitting to obtain the so-called non-twist splitting yarn.
In Japanese patent publication of unexamined applications Japanese Patent Laid-Open No. 59-116405, a manufacturing method for non-twist splitting yarn is disclosed as follows: multi-filaments are spun and oil finished to monofilament separately. The yarn tows are drawn at the first heating roller, then the second heating roller, and wound up. But in manufacturing the splitting yarn having more than 10 d.p.f. (denier per filament), the splitting yarn transferred onto the first heating roller swung right and left seriously, which is not suitable to mass production.
In addition, a method to decrease the swing occurred onto the first heating roller was disclosed in Japanese patent publication of unexamined applications Japanese Patent Laid-Open No. 3-16154, which comprised a cooling roller established ahead of the first heating roller to increase the pre-tension to the multifilaments, but the oiling tension before the cooling roller still too low. This is not suitable for the improvement and will increase the facility costs.
Similar invention such as Japanese patent publication of unexamined applications Japanese Patent Laid-Open No. 2000-64118, which disclosed a manufacturing method for a synthetic splitting yarn by using one set driven cooling roller established ahead of the first heating roller, then oiling the spun yarn and contacting the pear surface finished godet roller having dynamic friction coefficient of 0.10~0.35 &mgr;m. But detailed explanation is not done how surface roughness of a godet roller controls the swing of a splitting yarn.
No matter what the polyester yarn having high denier in monofilament may be manufactured by direct manufacture of monofilament yarn or combining multi-tow of filaments, then splitting to obtain the non-twist splitting yarn. All documents but the above mentioned documents seem to study the swing of yarn to elevate productivity, there is no invention to solve how to improve the bad packaging and white powder occurred in the post stage texturing of polyester yarn having high denier.
Means to solve the Problems
By carefully reviewing the deficiencies occurred in the previous manufacturing technologies of the polyester yarn having high denier in monofilament by using direct spin drawing process such as the insufficient cooling, the swing of the splitting yarn transferred onto the godet roller and bad packaging, white powder occurred when weaving, the inventor discovers that quenching effect can be effectively reached by decreasing the temperature of quenching air tube while not increasing the length of the quenching air tube, decreasing the swing of the splitting yarn transferred onto the godet roller can be reached by decreasing the surface roughness of godet roller to increase the friction between the yarn tow and the godet roller surface. To enhance the endurance of surface roughness of the godet roller, chrome plating treatment onto the godet roller surface is adopted to offer suitable oiling and heating condition, and polyester yarn excellent in yarn transferring, packaging and loosing with no white powder occurred when weaving is obtained so as to complete the present invention.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a manufacturing method for polyester yarn excellent in yarn transferring, packaging and loosing with no white powder occurred when weaving, which is heating polyester polymer of inherent viscosity (IV) 0.5~0.7 and melting point of 245~265° C. to melt, filter and extruding in constant amount by direct spin drawing of monofilament yarn or combining multi-tow of filaments, then splitting to obtain polyester yarn having high denier in monofilament, characterized in comprising the following steps:
a. uniformly spinning said constant amount extruded polyester melt through spinneret orifices to obtain the filament tows, passing said spun filament tows under spinneret to uniformly cooled to solidify in the quenching air tube, wherein said quenching air tube is equipped with chilling water tubular coil to keep the temperature of quenching air at 10~15° C.;
b. oiling said cooled filament tows, then texturing by the godet roller of direct spin drawing machine, wherein the surface of said godet roller are treated by chrome plating to make the surface roughness of first heating roller in Ra0.025 to 0.1 &mgr;m and the surface roughness of second heating roller in Ra0.1 to 0.5 &mgr;m;
c. drawing said filament tows between said first heating roller and second heating roller with drawing ratio of 3.5~5 times on the basis of the initial length of said filament tows, the temperature of said first heating roller was set at 85~105° C., while the temperature of said second heating roller was set at 130~160° C.;
d. obtaining spin drawing yarn (SDY) of d.p.f. 5 d~55 d by using said conditions, EO/PO (ethylene oxide/propylene oxide) content of spinning finish in oiling is set at 50%~90%.
In manufacturing synthetic fiber, the higher the d.p.f., the more the length of quenching air tube needed is well-known to the person ordinarily skilled in synthetic fiber manufacture art. In fact, it is not feasible to increase the length of quenching air tube only simply to cool said spun filament tows.
To obtain appropriate quenching for polyester filament tow of d.p.f. 5 d~55 d, the temperature of quenching air tube used in this invention is set at 10~15° C. by installing quenching air source with cooling coil. This will lead the filament tow not too soft to normally produce when oiling onto the oil roller. The requirement of the temperature of quenching air tube used is set at 10~15° C., which is suitable to produce polyester yarn of d.p.f. 5 d~55 d to overcome insufficient cooling due to polyester yarn of higher d.p.f. If the temperature of quenching air tube used is below 10° C., there will be difficult in design itself and may lead higher investment cost; while if the temperature of quenching air tube used is over 15° C., cooling of the filament tow is insufficient and may lead to unstable oiling due to lower tension in filament tow itself, and will frequently cause break in spinning and abnormal dyeability. But if increase the cooling time and lengthen the quenching air tube for the sake of sufficient cooling, this will increase the investment cost.
The cooling media added in the chilling water
Bacon & Thomas PLLC
Edwards N.
Nan Ya Plastics Corporation
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