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BACKGROUND OF THE INVENTION
The present invention relates to a melt spinning apparatus for producing a
plurality of yarns.
In the production of yarns by melt spinning, one distinguishes between
undyed, unicolored, and multicolored yarns, which require different
spinning apparatus. In particular in the production of multicolored carpet
yarns, apparatus are used, which extrude in one spinning position a
plurality. of filament bundles and subsequently combine these filament
bundles to a yarn. Such apparatus is described, for example, in EP 0485871
and corresponding U.S. Pat. No. 5,251,363. In the known apparatus, an
extruder produces a corresponding melt flow for each color. For each
color, the spinning position produces one filament bundle, with all
filament bundles being combined to the multicolored yarn. Thus, a
plurality of extruders are associated to the spinning position. In
practice, a plurality of spinning positions are arranged side by side. In
this arrangement, the melt flows of the extruders are distributed to the
individual spinning positions by a plurality of distributor pumps.
Depending on the design of the distributor pump, one distributor pump
supplies a plurality of spinnerets at the same time. These spinnerets are
associated respectively to one spinning position. Such spinning apparatus
are thus laid out according to the number of the dyes used for the
production of a multicolored yarn per spinning position.
However, in practice, it is desired to produce with such a spinning
apparatus also unicolored yarns. Yet is it known, that unicolored yarns
have a lower denier than multicolored yarns. Thus, the production of
unicolored or undyed yarns with the known apparatus is possible only with
a considerably lower output, or even impossible in the case of very low
yarn deniers.
Furthermore, it is necessary that all spinning positions connected via the
controlled melt flow system produce a yarn of the same color and kind. In
particular, in the case of a dye change, high production losses are
incurred, until all spinning positions connected to the controlled melt
flow system are changed to the new dye.
It is therefore the object of the invention to further develop a spinning
apparatus of the initially described kind such that it is possible to
produce multicolored, unicolored, or undyed yarns with a substantially
unchanged output. A further object of the invention is to provide an
apparatus with a flexible control of the melt flow and yarn path adapted
to the respectively produced yarn.
SUMMARY OF THE INVENTION
The above and other objects and advantages are achieved by the provision of
a melt spinning apparatus and method which includes at least one extruder
for producing a polymer melt flow, and at least two spinning positions
arranged side by side and with each spinning position including at least
one spinneret. Also, a distributor system is provided for delivering a
portion of the melt flow to each spinneret of each spinning position and
such that each spinning position extrudes a filament bundle composed of a
plurality of strandlike filaments.
The spinnerets of adjacent spinning positions are arranged side by side in
such a manner that at least one filament bundle of the one spinning
position can be combined to a yarn with at least one filament bundle of
the adjacent spinning position. The special advantage of this
configuration lies in that it is possible to vary the number of the
filament bundles that are combined to a yarn. Thus, there exists the
possibility of combining in the production of a multicolored yarn a larger
number of filament bundles to a yarn, and of combining in the production
of a unicolored or an undyed yarn a lesser number of filament bundles or
only one filament bundle. This permits producing with the same output both
a multicolored yarn of a high denier and a unicolored yarn of a low
denier. For example, in a spinning apparatus with two spinning positions,
which comprise each three spinnerets, it is possible to selectively
produce three yarns by combining respectively two adjacent filament
bundles, or two yarns by combining three adjacent filament bundles.
However, it is also possible to spin, without combining, each filament
bundle to one yarn.
Each of the spinning positions comprises a plurality of serially aligned
spinnerets and the spinnerets of adjacent spinning positions are serially
aligned. This facilitates the production of a plurality of parallel side
by side yarns at the same time.
To produce at least one yarn, which is formed by combining two filament
bundles of adjacent spinning positions, it is desirable to have the
spacing between a spinneret arranged at the edge of the one spinning
position and an adjacent spinneret of the other spinning position be the
same or insignificantly greater than the spacing between two adjacent
spinnerets of one of the spinning positions. This ensures that the spacing
between the spinnerets and the converging points of the yarns is the same
for each yarn. With that, it is possible to use in like manner yarn guide
arrangements of the spinning apparatus both in the production of
multicolored yarns and in the production of unicolored yarns.
In the case that a plurality of filament bundles of adjacent spinning
positions are combined to a yarn, it will be advantageous when the spacing
between two spinnerets of adjacent spinning positions is made smaller than
the spacing between the spinnerets of one of the spinning positions. Such
a construction of the spinning apparatus makes it likewise possible to
combine the filament bundles in several planes.
In one preferred embodiment, each of the spinning positions comprises a
separate housing for three serially arranged spinnerets. In the production
of multicolored yarns, each spinneret of a spinning position extrudes a
filament bundle of a certain color, so that a three-colored yarn can be
produced. In the production of unicolored or undyed yarns, the three
spinnerets of a spinning position produce each a filament bundle of the
same color. In this instance, three yarns are simultaneously produced in
each pair of spinning positions. This embodiment is especially
advantageous for producing BCF yarns in a corresponding further treatment
of the yarns.
The distributor system includes a plurality of distributor pumps, and a
valve unit may be provided which interconnects the extruders and the
distributor pumps. The valve unit has a plurality of switching positions,
which provides the advantage that in the production of a unicolored or an
undyed yarn, one spinning position processes the melt of one extruder.
With that, it is possible to produce yarns of a great uniformity in their
composition.
In one of the switching positions of the valve unit, each spinning position
is associated to one extruder. Thus, it is possible to operate the
spinning positions in the spinning apparatus with differently dyed
filament bundles for producing colored yarns. A special advantage of the
invention lies in that the dye changes can be performed in the spinning
position rapidly and without great production losses.
In the second switching position of the valve unit, each of the distributor
pumps of a spinning position is associated to one of the extruders, so
that the spinnerets of the spinning position extrude the polymer melts of
a plurality of extruders. In this adjustment, it is advantageous to
produce multicolored yarns.
Naturally, the valve unit could also be formed by a known stationary
distributor block, which is exchanged for a second distributor block, when
need arises. It would also be possible to construct the distributor block
with a plurality of plates, so that one plate or a portion of the plates
is made exchangeable for changing the melt flow.
A takeup device may be provided which has a plurality of winding positions
for winding each of the yarns to a package. In this takeup device, the
number of winding positions is greater than the number of the upstream
spinning positions. This permits associating one winding position to each
spinning position in the production of multicolored yarns. In this
instance, the winding positions that are arranged between two adjacent
spinning positions, remain inoperative. Only in the production of
unicolored yarns, is one package wound in each winding position.
To combine the filament bundles, a yarn treatment device is proposed, which
comprises a plurality of treatment stations. The number of the treatment
stations is greater than the number of the upstream spinning positions.
Thus, a change in the production processes will make is unnecessary to
revamp the stations for producing the corresponding number of yarns. In
the production of unicolored yarns, each treatment station treats one
yarn.
Advantageously, the treatment stations are designed and constructed as
texturing nozzles, so that it is possible to produce a crimped yarn.
However, it is also possible to combine the filament bundles within the
treatment station by an entanglement nozzle. To produce a crimp in the
yarn, the filament bundles are textured before they enter the entanglement
nozzles.
The use of the apparatus according to the invention distinguishes itself by
its great flexibility in the production of yarns. With the use of the
apparatus, it has been accomplished to produce qualitatively superior
yarns in a unicolored or multicolored version.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, further advantages are described with reference to
several embodiments and to the attached drawings, in which:
FIG. 1 is a schematic view of a first embodiment of the apparatus according
to the invention;
FIG. 2 is a schematic view of a further embodiment of the apparatus
according to the invention; and
FIGS. 3.1 and 3.2 are schematic views of the controlled melt flow system of
an apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 schematically illustrates a first embodiment of the apparatus
according to the invention. To produce a plurality of melt flows of a
plastic, extruders 1.1, 1.2, and 1.3 are provided. At its outlet, the
extruder 1.1 connects, via a melt line 2.1, to a valve unit 3. Likewise,
the extruders 1.2 and 1.3 connect each, via a melt line 2.2 and 2.3, to
the valve unit 3. The valve unit 3 will be described in greater detail
below, and it possesses three melt outlets which connect respectively, via
melt lines 6.1, 6.2, and 6.3, to a distributor pump 4.1, 4.2, and 4.3. The
distributor pump 4.1 is controllably driven by a drive 5.1. Likewise, the
pumps 4.2 and 4.3 are driven by drives 5.2 and 5.3.
The distributor pumps 4.1, 4.2, and 4.3 are each designed and constructed
as two-delivery pumps, so that each pump has two outlets and divides the
melt flow supplied through melt line 6 into two equal partial flows. With
its first outlet, the distributor pump 4.1 connects, via a distribution
line 7.1 to a first spinneret 9.1. The spinneret 9.1 is accommodated in a
spinning position 8.1. With its second outlet, the distributor pump 4.1
connects, via a distribution line 7.2, to a spinneret 9.4, which is
arranged in a second spinning position 8.2.
The apparatus of FIG. 1 is shown by way of example with two spinning
positions 8.1 and 8.2. In practice, as many as eight to ten spinning
positions are operated side by side in one apparatus.
The spinning positions 8.1 and 8.2 are separately housed and each comprises
three spinnerets. The spinneret 9.2 of the first spinning position 8.1,
which is adjacent the spinneret 9.1, connects via a distribution line 7.3
to an outlet of distributor pump 4.2. The third spinneret 9.3 of the
spinning position 8.1 connects via a distribution line 7.5 to an outlet of
distributor pump 4.3.
The spinnerets 9.1, 9.2, and 9.3 are serially arranged, one after the
other, with one of the distributor pumps being associated to each
spinneret. The spinnerets 9.4, 9.5, and 9.6 of the second spinning
position 8.2. are also connected in series, with the spinning positions
8.1 and 8.2 being mounted in the apparatus in the same plane and at the
same height. The spinnerets 9.4, 9.5, and 9.6 of the spinning position 8.2
connect each to one of the pumps via the separately extending distribution
lines 7.2, 7.4., and 7.6.
In the case of this spinning position, distributor pump 4.1 is associated
to spinneret 9.4, distributor pump 4.2 to spinneret 9.5, and distributor
pump 4.3 to spinneret 9.6. Each of the spinnerets 9.1-9.6 produces a
filament bundle 10.1-10.6. The filament bundle consists of a plurality of
strandlike filaments, which are extruded from the nozzle bores of the
spinneret. The filament bundles 10.1-10.6 advance through a cooling zone,
so that the filaments of the filament bundles solidify. Subsequently, the
individual filaments of the filament bundle 10 are combined via a yarn
guide 11, which is followed in the direction of the advancing yarn by a
yarn treatment device 12. The yarn treatment device possesses a plurality
of work stations, which are each formed by a texturing nozzle 13. In FIG.
1, the yarn treatment device 12 comprises a total of three work stations.
A first work station, which is formed by texturing nozzle 13.1, receives
the filament bundles 10.1 and 10.2. Inside the texturing nozzle 13.1, the
filament bundles 10.1 and 10.2 are compressed to form a common yarn plug.
Subsequently, the yarn plug is disentangled to a yarn 15.1. The yarn 15.1
is removed from the plug by a takeup station 16 and wound to a package
20.1 in a winding position 17.1.
In the second treatment station 13.2, the filament bundles 10.3 and 10.4
are combined. The filament bundle 10.3 is produced in the first spinning
position 8.1 by spinneret 9.3. The second filament bundle 10.4 is produced
in the second spinning position 8.2 by spinneret 9.4. Both filament
bundles are combined by texturing nozzle 13.2 to a yarn 15.2. To this end,
the spinning positions 8.1 and 8.2 are arranged relative to each other
such that the external spinnerets 9.3 and 9.4 are at a distance from each
other, which is substantially the same as the spacing that is maintained
between the spinnerets of spinning position 8.1 or spinning position 8.2.
Thus, it is possible to produce the yarn 15.2 by combining the adjacent
filament bundles 10.3. and 10.4 of both spinning positions 8.1 and 8.2
with the same controlled yarn advance as in the adjacent work stations.
The yarn 15.2 is wound to a package 20.2 in a winding position 17.2 of
takeup station 16.
The third work station is formed by texturing nozzle 13.3. In the texturing
nozzle 13.3, the filament bundles 10.5 and 10.6 of spinning position 8.2
are combined to a yarn 15.3. Likewise, in this instance the filament
bundles 10.5 and 10.6 are compressed to a yarn plug in the texturing
nozzle and subsequently disentangled to the yarn 15.3.
The takeup station 16 comprises a winding position for each work station,
so that a total of three winding positions 17.1, 17.2, and 17.3 are
provided. For the winding positions 17.1-17.3, the takeup station 16
comprises a long winding spindle 22 mounted in cantilever fashion. The
winding spindle 22 is unilaterally supported and can be driven via a drive
21. In each winding position 17.1-17.3, the winding spindle mounts a tube
19.1-19.3, which serves to receive the package. Each yarn 15.1-15.3
advances over a yarn guide 18 to the takeup station 16. To deposit the
yarn on the package, a traversing device reciprocates the yarn along the
length of the package. An illustration of the traversing device has been
omitted.
In the spinning apparatus shown in FIG. 1, additional devices for guiding,
drawing, thermally treating, or entangling the yarn may precede or follow
the yarn treatment device 12. For example, it is possible to withdraw the
filament bundles 10.1-10.6 from the spinnerets 9.1-9.6 by means of a feed
system.
FIG. 1 illustrates the use of the apparatus for producing unicolored or
undyed yarns. The extruders 1.1, 1.2, and 1.3 produce a unicolored or an
undyed polymer melt of a predetermined polymer. Thus, the same polymer
melt is supplied via the distributor pumps 4.1, 4.2, and 4.3 to each
spinneret of spinning positions 8.1 and 8.2. This causes each spinneret
9.1-9.6 to produce a homogeneous filament bundle. The combination of the
filament bundles in the texturing nozzles 13.1, 13.2, and 13.3 thus leads
to a yarn that is homogeneous in its composition.
FIG. 2 is a schematic view of a further embodiment of an apparatus
according to the invention. The spinning apparatus of FIG. 2, however,
differs only in the kind of treatment of the filament bundles as well as
in the combination of the filament bundles to yarns. The melt flow control
system until the production of the filament bundles is identical with the
apparatus of FIG. 1. To this extent the foregoing description is herewith
incorporated by reference.
In the spinning apparatus shown in FIG. 2, a plurality of texturing nozzles
23.1-23.6 are arranged side by side between the takeup station 16 and the
spinning positions 8.1 and 8.2. For each spinneret 9.1-9.6 of spinning
positions 8.1 and 8.2, a texturing nozzle 23.1-23.6 is arranged in the
yarn advance plane of the produced filament bundles 10.1-10.6. Between the
texturing nozzles 23.1-23.6 and the takeup station 16, the yarn treatment
device 12 is arranged for combining the filament bundles. The yarn
treatment device comprises a total of two work stations, which are each
formed by an entanglement nozzle 14.1, 14.2, and 14.3.
In the situation shown in FIG. 2, the apparatus is used to produce a
multicolored yarn. To this end, a melt of a certain color is produced in
each of the extruders 1.1, 1.2, and 1.3. Via the valve unit 3, the melt
flow of an extruder is supplied to one of the distributor pumps 4. Thus,
for example, the extruder 1.1 may connect to distributor pump 4.1, the
extruder 1.2 to distributor pump 4.2, and the extruder 1.3 to distributor
pump 4.3. Each distributor pump now carries a differently colored polymer
melt. Through the distribution lines 7.1-7.6, the distribution of the
partial melt flows occurs such that in each spinning position 8.1 and 8.2
three differently colored filament bundles are produced. The filament
bundles 10.1 and 10.6 advance each through a texturing nozzle. In so doing
they are compressed to a plug and subsequently disentangled to a crimped
filament bundle. The crimped filament bundles 10.1, 10.2, and 10.3 of one
spinning position 8.1 are then combined in the entanglement nozzle 14.1 to
a yarn 24.1. In the winding position 17.1 of takeup station 16, the yarn
24.1 is wound to a package 20.1. After texturing by the entanglement
nozzle 14.3, the filament bundles 10.4, 10.5, and 10.6 of the second
spinning position 8.2 are combined to a yarn 24.2. The yarn 24.2 is wound
in the winding position 17.3 of the takeup station 16 to a package 20.3.
The center work station of the yarn treatment device 12 as well as the
center winding position 17.2 of the takeup station 16 remain idle. In the
production of multicolored yarns, it is advantageous to produce one yarn
per spinning position, so that the work station and the winding station
respectively remain out of operation. However, it is also possible to
provide yarn treatment devices and winding stations in the production of
multicolored yarn with the number of work stations and winding positions,
which corresponds to the number of spinning positions. Likewise, it is
possible to provide a treatment device and winding position for each
spinneret of a spinning position.
FIGS. 3.1 and 3.2 schematically illustrate an embodiment of a controlled
melt flow system in the spinning apparatus of the present invention. In
these Figures, an illustration of the combination as well as further
treatment of the filament bundles and the yarn has been omitted. FIG. 3.1
illustrates the controlled melt flow system in the production of
multicolored yarns. FIG. 3.2 shows the controlled melt flow system in the
production of unicolored or undyed yarns. Unless otherwise specified, the
following description will apply to both Figures.
For the production of the polymer melts, two extruders 1.1 and 1.2 are
provided. At their outlet, the extruders 1.1 and 1.2 connect, via melt
lines 2.1 and 2.2, to a valve unit 3. The valve unit 3 is manually
adjustable and can be adjusted between two switching positions. Through
the valve unit 3, the melt lines 2.1, and 2.2 are connected according to
one of the switching positions to melt lines 6.1, 6.2, 6.3, and 6.4. The
melt lines 6.1-6.4 connect respectively each to the inlet of a distributor
pump 4.1-4.4. Thus, the melt line 6.1 extends to distributor pump 4.1, the
melt line 6.2 to distributor pump 4.3, the melt line 6.3 to distributor
pump 4.2, and the melt line 6.4 to distributor pump 4.4. The distributor
pumps 4.1-4.4 are each designed and constructed as a two-delivery pump, so
that they comprise two outlets. The melt flow is divided by the
distributor pump 4 into two partial flows, and delivered via the
respective pump outlets to the thereto connected distribution lines
7.1-7.8. The distributor pumps 4.1-4.4 supply, via distribution lines
7.1-7.8, a total of four spinning positions 8.1-8.2, each having two
spinnerets 9. This results in an apparatus, which comprises four
side-by-side spinning positions 8.1-8.4 with the spinnerets 9.1-9.8. In
each of the spinnerets 9.1-9.8, a filament bundle 10.1-10.8 is produced.
The association of the distributor pumps to the spinning positions
provides that the distributor pumps 4.1 and 4.2 supply the spinning
positions 8.1 and 8.2. In this connection, the spinneret 9.1 of spinning
position 8.1 and the spinneret 9.3 of spinning position 8.2 are associated
to distributor pump 4.1. The spinneret 9.2 of spinning position 8.1 and
the spinneret 9.4 of spinning position 8.2 are associated to distributor
pump 4.2. Accordingly, the supply to spinning positions 8.3 and 8.4 occurs
in like manner by distributor pumps 4.3 and 4.4, so that the two
spinnerets of a spinning position are each associated to one distributor
pump.
FIG. 3.1 shows the valve unit 3 in its switching position I. In this
position, the melt flow from extruder 1.1 advances to distributor pumps
4.1 and 4.3. The melt flow from extruder 1.2 advances to distributor pumps
4.2 and 4.4. With that, it is realized that each spinning position 8.1 and
8.4 produces a filament bundle from the melt flow of extruder 1.1, and a
filament bundle from the melt flow of extruder 1.2. This controlled melt
flow system is thus in particular suitable for producing multicolored
yarns. In this process, the extruder 1.1 produces, for example, a melt
dyed blue, and the extruder 1.2 a melt dyed yellow. Thus, the spinning
positions 8.1-8.4 produce each a blue and a yellow filament bundle, which
are combined to a blue-yellow yarn.
In the situation shown in FIG. 3.2, the valve unit is in its switching
position II. In this switching position, the melt flow of extruder 1.1
advances to the distributor pumps 4.1 and 4.2. The melt flow of the
extruder 1.2 advances to the distributor pumps 4.3 and 4.4. With that, it
is accomplished that the spinning positions 8.1 and 8.2 process only the
melt of extruder 1.1, and the spinning positions 8.3 and 8.4 only the melt
of extruder 1.2. This controlled melt flow system is especially suited for
producing unicolored or even undyed yarns. In this process, it is possible
to produce in the spinning positions 8.1 and 8.2, for example, two blue
yarns, and in the spinning positions 8.3 and 8.4 two yellow yarns.
The valve unit shown in FIGS. 3.1-3.2 may also be used without difficulty
in a spinning apparatus of FIG. 1 or 2. To this end, the spinning
apparatus of FIG. 1 or 2 is enlarged by four spinning positions. In this
instance, two spinning positions each would be supplied by three
distributor pumps. Accordingly, in one of the switching positions of the
valve unit, one extruder melt line would be associated to a total of three
distributor pumps. The valve unit 3 would thus have three connections for
the extruders and nine connections for the distributor pumps. If one
looked now at the apparatus shown in FIG. 1, the valve unit 3 would be in
this instance in a switching position, in which the distributor pumps 4.1,
4.2, and 4.3 are simultaneously supplied by the extruder 1.1. The melt
flows from the extruder 1.2 and 1.3 would be supplied to the adjacent
spinning positions.
In the spinning apparatus shown in FIG. 2, the valve unit would
advantageously be accommodated in a switching position, in which the
distributor pump 4.1 is associated to extruder 1.1, the distributor pump
4.2 to extruder 1.2, and the distributor pump 4.3 to extruder 1.3.
The apparatus of the present invention is in particular suited for
producing BCF yarns, for example, from polyester, polyamide, or
polypropylene.
The apparatus shown in FIGS. 1, 2, 3.1 and 3.2 are by way of example. The
apparatus of the present invention may also be constructed with a
plurality of spinning positions, which comprise each only one spinneret,
and which are supplied by only one extruder. In such a spinning apparatus,
it is thus possible to spin from the filament bundle one yarn per spinning
position, or to spin one yarn from two filament bundles by combining two
adjacent spinning positions. With that, a great flexibility is
accomplished in the production of the yarns.
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