Title of Invention

A METHOD AND AN APPARATUS FOR SPINNING A SYNTHETIC MULTIFILAMENT YARN

Abstract A method and apparatus for spinning, drawing and winding a synthetic multi-filament: yarn, wherein the yam la subjected after drawing and prior to winding to a heat treatment for purposes of reducing Its shrinkage tendency. in the heat treatment, the yarn advances along an elongated heating surface closely adjacent thereto but substantially in no contact therewith. She heating surface has a surface temperature which is above the melt point of the yarn. During the heat treatment, the yam is subjected to a tension which is lower than the tension required for Plastic deformation. The yam wound by this method has a heat shrinkage tendency which is typically more than about 20%. PRICE: THIRTY RUPEES
Full Text

Tne presenr invention relates to a method and an apparatus for spinning, drawing, and winding a synthetic multi-filament yarn.
U.S. Patent No. 4,123,492 discloses a method and apparatus for the spinning, drawing, and winding of a synthetic multi-filament yarn in a single, continuous process. In such process, the yam tends to shrink, i.e., to shorten, in the package, thereby subjecting the wound yam to a very high tension which can. lead to the destruction of the package. The problem is especially serious in the winding of both nylon 6 and nylon 6.6 (polyamide) yams, and polypropylene yarns. It is therefore necessary to subject the yarn to a shrinkage treatment before winding, so as to remove its tendency to shrink. However, this additional procedure is undesirable for textile technological reasons, including the fact that the tendency of the yarn to shrink from heat is useful in many subsequent processing operations.
It is an object of the present invention to provide a method and apparatus for spinning a synthetic multi-filament yam which includes a shrinkage treatment which removes the tendency of the yarn to shrink in the package, yet does not significantly effect the tendency to shrinkage which is caused in particular by a heat treatment or by boiling, and which

is desirable and favorable in subsequent processing operations.
It is a more particular object of the present invention to provide a method and apparatus of the described type which includes a treatment which reduces the so-called package shrinkage, i.e., the tendency to cold shrinkage, to a harmless degree, without significantly effecting the hot shrinkage tendency which is useful in many subsequent processing operations.
Summary of the Invention
The above and other objects and advantages of the present invention are achieved by the provision of a method and apparatus which includes the steps of extruding a polymeric melt to form a plurality of advancing filaments, and gathering the filaments to form an advancing yarn. The advancing yarn is then subjected to a drawing operation, and thereafter the advancing yam is heated by guiding the advancing yarn . along a path of travel which is adjacent but at least essentially spaced from an elongate heating surface. The heating surface is heated to a temperature which is above the melting temperature of the yarn, and during such heating the advancing yarn is subjected to a tension which is insufficient to cause a plastic deformation of the yarn. Finally, the advancing yarn is wound into a package.
Preferably, the temperature of the heating surface is more than about 100'C above the melting temperature of the yarn, and most preferably, the temperature is between about 200 and 300C: above the melting temperature of the yarn.
During the heating step, the yarn is subjected to tension which is not greter than about 0.3 cN/dtex during the heating step, and preferably.

the tension is between about 0. 1 and 0.2 cN/'dtex during the heating step.
The resulting yarn has a hot shrinkage tendency which is greater than about 3%, and the tendency is preferably more than 20%, and most preferably it is between about 30% and about 40%.
An advantage of the present invention is that the textile technological properties of the yarn are not adversely affected by the shrinkage exeatment of the invention. In particular, after unwinding, the yam may still exhibit a high hot shrinkage tendency, which is expressed, for example, as boiling shrinkage. Also, the feed rolls or feed systems, which advance the yarn into the shrinkage treatment zone or withdraw it therefrom, need not be heated. This is not only a substantial simplification of mechanical engineering, but also permits a more favorable control of the process. During the treatment, the yarn is subjected only to a yarn tension which is lower than the tension required for drawing the already oriented yarn. In the case of polyamide, polyester or polytrimethylene terephthalate yams, the temperature of the heating surface is preferably higher than 350C, in the case of polypropylene yarns the surface teniperature is preferably higher than 200C.
The present invention permits that yarn to advance in the spin zone and/or shrinkage zone and/or takeup zone under very little tension, without incurring the risk of an unsteady threadline or the formation of laps on the godet or another disturbance of the process.
In the preferred embodiment, the yarn is guided along the heating surface by one or more short guides which are distributed along the surface. This
serves the purpose of guiding the yarn at a precisely
defined distance from the heated surface. A distance
from 0.5 to 3.5 mm is desirable.

AS noted above, it is possible to advance the yam in the shrinkage treatment zone under very little tension. This permits the process to be simplified, in that the yarn tension is adjusted such that it is simultaneously suitable for winding.
In one embodiment, the heat, treatment occurs between two yam feeding godets. This provides an advantage in that it is possible to edjunt the yam tension very uniformly and, thus, the shrinkage in a very controlled manner.
In the short spinning process, the yams being produced are very susceptible to shi-inkage, and they present great problems during the takeup. In this instance, it will be advantageous Co utilize an embodiment of the invention wherein the yarn is advanced directly from the spin box to the take-up winder without the use of yam feeding godets, and at a withdrawal speed which is greater than 5000 m/min, and preferably between 6000 and 7500 m/min.
The method of the present invention is suitable for all polymers in use. It allows to produce a high-quality package of polyester yarn yh;.ch has still a hot or boiling shrinkage ol! rrore them 20% after unwinding.
Especially important is the shrinkage-free treatment for polyamides. The currtently conducted shrinkage-free treatments, in particular with vapor, result in an overall reduction of the snrinkage tendency- While the method of the present invention permits removal only of the shrinkage in the package, the shrinkage tendency remains unslrif.ngei when heat is supplied, or it remains adjustablt by other parameters of the process control.
This applies in like manner to polypropylene yams, which present in the conventional process significant-problems daring winding.

An especially advantageous method of drawing in accordance with one embodiment of. the present invention includes withdrawing the yarn from the spinneret by means of a godet at a high speed of more than 3,500 m/min. and advancing same through a narrow heating tube, in the heating tube, the yam undergoes drawing as a result of tension and heating. Until now, this method has been impractical for materials with a strong shrinkage tendency, in particular nylon and polypropylene, since by this kind of drawing the yams are imparted a high tendency to shrinkage in the package. However, the combination with the method of the present invention allows this draw method to be applied to all types of materials.
Prior to the heat treatment, the yarn may be subjected to a drawing operation wherein the yarn is guided closely adjacent, but at least essentially spaced from an elongate heater which is neated to a temperature higher than the melt point of the yarn, preferably from 100' to 300C above the melt point, and the yam is tensioned to an extent leading to a plastic deformation of the yarn. Despite the low yjarn tension in the draw zone, the yam forms a precisely localized yield point and can be totally drawn. For the formation of a precisely established yield point, the method may be further improved by grinding the advancing yarn over guides, while partially looping the same, before entering into the draw zone.
A further, advantageous variant of the method for the spinning includes withdrawing the yarn from the spinneret at a speed of more than 500 m/min, and so as to result in the simultaneous drawing of the yarn, as is known from EP 0 539 866 A2.
The apparatus of the present invention distinguishes itself in that despite the very high yarn speeds, the heating surface is very short, in; particular, in a range from 300 to 1000 mm.

The heater of the present invention may take the form of a generally U-shaped body or rail, which defines a longitudinal heating surface in a groove thereof and with the yarn being guided to have essentially no contact with the heating surface. This construction permits a simple operation and, in particular, a simple selection of the distance at which the yam advances from the heated surface. In this embodiment, this distance may be predetermined by yarn guides as a function of the yam material, the denier, the number of filaments, the yarn speed, and the adjusted temperature of the heating surface.
The body or rail of the heater may comprise two separate body segments which are positioned in an end to end relationship, and which have separate temperature controls. Besides a smooth advance of the yarn, this embodiment allows in particular a stepped temperature control that is adapted to the process. For example, a first step is controlled in a temperature range from 450 to 550C, and the second step in a temperature range from 400 to 500C.
The invention applies to all polyamides, polyester, as well as polytrimethylene terephthalate (PTT). In the case of polypropylene, the temperatures are correspondingly lower, preferably by 100C to 200'C.
A combination of the invention which is especially favorable in terms of process er.ginefering, utilizes in the draw zone a narrow tube surrounding the threadline, into which the yarn advancing from the spinneret enters without passing over a godet. This simple solution of mechanical engineering becomes possible for all materials only as a result of this invention. Where the yam is withdrawn from the spinning zone by means of an unheated godet or the like, and advanced to the draw zone, the invention requires no special measures to reduce the shrinkage

tendency of the yarn already in the draw zone. Thus, additional possibilities of adjustment are obtained, so as to modify the other yam properties, in particular, tensile strength and elongation. It is possible to spin in particular highly oriented or fully oriented yams in a continuous process.
Important advantages result from the shrinkage treatment. The invention allows the so-called "package shrinkage", i.e. the tendency to cold shrinkage, to be reduced to a harmless degree, or to be eliminated, without thereby adversely effecting the hot shrinkage tendency, i.e., boiling shrinkage or hot air shrinkage. From the viewpoint of textile or technology, it is not desirable to adjust the hot shrinkage tendency to the requirements of winding, but to the requirements of subsequent processing operations. Thus, for example, a certain shrinkage tendency is desired in a sewing yam, so that the seam can adjust itself to the shrinkage of the fabric. When employing the yam for hosiery, the leg shape is obtained, in that the untreated hose is pulled over a flat board and adjusts itself to same by heat treatment and shrinkage. In other fabrics, such as corduroy, shrinkage causes the density to increase. In all these cases, the requirement for shrinkage-free winding in accordance with the invention has no disturbing influence on the tendency to heat shrinkage that is to be achieved.
Accordingly the present invention provides a method of spinning a synthetic multi-filament yam comprising the steps of extmding a polymeric melt to form a plurality of advancing filaments, and gathering the filaments to form an advancing yam, drawing the advancing yam, and thereafter

heating the advancing yam by guiding the advancing yam along a path of travel which is adjacent but at least essentially spaced from an elongate heating surface, with the heating surface being heated to a temperature which is above the melting temperature of the yam, and while subjecting the advancing yam to a tension which is insufficient to cause a plastic deformation of the yam, and then winding the advancing yam into a package.
Accordingly the present invention also provides an apparatus for spinning a synthetic multi-filament yam as herein-above described, said apparatus comprising means for extruding a polymeric melt to fomi a plurality of advancing filaments, and gathering the filaments to form an advancing multi-filament yam, means for drawing the advancing yam and so as to define a drawing zone, means defining a draw-free zone downstream of said drawing zone and wherein the advancing yam is subjected to a tension insufficient for drawing of the yam, a heater positioned within the draw-free zone and comprising an elongate heating surface, and means for heating the heating surface to a temperature which is above the melting temperature of the yarn, and a winder positioned downstream of said heater for winding the advancing yam into a package.
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, taken in conjunction with the accompanying drawings, in which:
Figure 1 is a schematic view of the spinning process and the essential elements of an apparatus which embody the present invention;

Figures 2a-2c illustrate an embodiment of a heating apparatus for use with the invention;
Figure 3 is a schematic view of a modified spinning process and apparatus which embodies the invention;
Figure 4 is a schematic view of a further modified spinning process and apparatus which embodies the invention;
Figure 5 is a schematic view of another modified spinning process and apparatus which embodies the invention; and
Figure 6 is a schematic view of; still another modified spinning process and apparatus which embodies the invention.
Detailed Description of the Preferred Embodiments Referring more particularly to the drawings. Figure 1 illustrates a melt spinning apparatus wherein a yarn 1 is spun from a thermoplastic material. The thermoplastic material is supplied through a hopper 2 to an extruder 3, The extruder 3 is driwen by a motor 4, which is controlled by a control unit 49. in the extruder 3, the thermoplastic material is melted. The work of deformation (shearing energy), which is applied by the extruder 3 to the material, assists in the melting process. In addition, a heater, for example in the form of a resistance heater 5, is provided, which is controlled by a heating control unit SO. Through a melt line 6, which includes a pressure sensor 7 for measuring the melt pressure so as to control the pressure and speed of extruder 3, the melt reaches a gear pump 9, which is driven by a pump motor 44.' The pump motor 44 is controlled by a control unit 45, so as to permit a very fine adjustment of the pump speed. The pump 9 transports the melt to a heated spin box 10, the underside of which mounts a spinneret lA. From the, spinneret ll, the melt emerges in the form of fine

strands of filaments 12. The filament strands advance through a cooling shaft 15. In the cooling shaft 15, an air current is directed crosswise or radially to the web of filaments 12, thereby cooling the filaments.
At the outlet end of cooling shaft 15, the web of filaments is combined to form the yarn 1. The yarn is withdrawn from the cooling shaft 15 and from spinneret 11 by a godet 54. The yarn loops several times about godet 54. To this end a guide roll 55 is used, which is axially inclined relative to the godet 54. The guide roll 55 is freely rotatable. The godet 54 is driven by a motor at a preadjustable speed. This withdrawal speed is by a multiple higher than the natural exit speed of the filaments 12 from the spinneret, thereby subjecting the yarn to a very high tension, which leads to its drawing. The drawing is assisted by a heating tube 20 which defines a draw heating zone 31. The heating tube 20 measures, for example, 1.150 m long. It is heated to a temperature, which is for polyester and PTT from 140' to 180'C, for polypropylene from 100 to 150C, and for polyamide from 140' to 220'C. The yield point of the yam is located in an inlet region of this heating tube. The temperature control in the further extension of the heating tube permits the properties of the yarn, such as its strength, boiling shrinkage, and elongation, to be adjusted. Such a heating tube is described, for example, in DE 38 08 854, which corresponds to U.S. Patent No. 4,902,461, and also in DE 37 20 337.
The godet 54 is followed by a second godet 16 with a guide roll 17, before the yarn 1 is wound in a takeup 30 to a package 33.
Arranged between godets 54 and 16 is a heater a in accordance with the invention. The heater 8 is an elongate body or rail a long which the yarn advances slightly spaced apart therefrom. This elongate heater is divided into several segments, namely a first

heating zone 27 and a second heating zone 38 as illustrated, which may be heated independently of each other, as is described in more detail below.
From godet 16 of Figure 1 or Figure 3, the yam 1 advances to a so-called "apex yarn guide" 25 and thence to a traversing triangle 26. Not shown in Figure 1 is the traversing mechanism, which comprises two oppositely rotating blades that reciprocate the. yam 1 over the length of package 33. In so doing, the yam loops about a contact roll (not shown) downstream of the yam traversing mechanism. The contact roll lies against the surface of package 33. It serves to measure the surface speed of package 33, which is formed on a tube 35. The tube 35 Is clamped on a winding spindle 34. The winding spindle 34 is driven by a motor and a control unit such that the surface speed of package 33 remains constant. To this end and for use as a control variable, the speed of the freely rotatable contact roll is sensed.
It should be noted that the yam traversing mechanism may also be a standard cross-spiralled roll with a yam guide traversing in the cross-spiralled groove.
In one embodiment, a polypropylene yam with a filament denier from 0.7 to 3 dtex is spun and withdrawn from the spinneret 11 by godet 54 and at a speed higher than 3,500 and 4,500 m/min,, the yam being subjected to a sudden heating in heater 8. The godet 16 has a circumferential speed, which is not higher than that of godet 54. Thus, the yarn is not drawn/ and it is essentially relaxed as it passes through the heater, in this embodiment, the heater is operated at very high temperatures above the melting point, i.e., substantially above 220'C. The first zone 27 of the elongate heater is heated to 330'C and the second zone 28 to 150C.This allows as acequate relaxation treatment between godets 16 and 54 to be

achieved, which continues even into the takeup zone. Preferably, the temperatures of the first heating zone 27 are somewhat higher than those of the second heating zone 28, nanely in a preferred range from 250* to 550C. The temperature of the second heading zone 29 is preferably from 150 to 450'C. The yarn tension between godets 54 and 16 can be adjusted to less than 0.1 cN/dtex, taking into account the speed difference and the shrinkage forces. This range is especially advantageous for activating or eliminating the tendency to cold shrinkage. The temperature control, in particular in the second heating zone 28, permits the hot shrinkage tendency to also be influenced in a controlled manner, without thereby adversely affecting the cold shrinkage tendency that is detrimental to winding.
A further godet 21 and guide zoll 22 may be arranged upstream of godet 54, as is shown in Figure 3. In this instance, a subsequent drawing occurs between these godets 21 and 54. To this end, the speed of godet 54 is adjusted higher than the speed of godet 21. A tension is applied, which leads to a further

deformation of the yarn I. Preferably, a further heat treatment also occurs between these two godets. To this end, a heater 24 is shown in Figure 3. The heater has a heating surface 29 that faces the yarn 1. The yarn 1 advances therealong without contacting, but closely adjacent this heated surface 29, at: a distance from 0.5 to 5 mm. The surface temperature is adjusted higher than the melting point of the particular polymer. This subsequent drawing and the sudden heating provided therein allow to achieve an influencing of the crystal structure in the meaning of a greater long-term stability of the yam. As a result, the effectiveness of the subsequent treatment

between godets 54 and 16 is amplified, and the pacJcage shrinkage and the tendency to shrink on the package are further reduced.
It should be noted that otherwise the method shown in Figure 3 corresponds to that described above with respect to Figure 1. When the methods of Figures 1 and 3 are employed, it is possible to wind subsequently both soft and especially shrinkage-sensitive, hard packages, which will not exhibit a detrimental package shrinkage with damage or destruction of the package, even in their long-term behavior. Both methods are carried out in that the yam is withdrawn from the spinneret H at a very high speed of more than 3,500 m/min by means of godet 54 in the instance of Figure 1, and by means of godet 21 in the instance of Figure 3. In the case of Figure 3, the subsequent drawing may amount to another 10 to 30%.
The modification of the crystalline structure and the increase of the length stability, as provided by the process of Figure 3, may also be produced in a method as shown in Figure l, in that the heating tube 20 in the draw heating zone 31 is replaced, as shown in Figure 4, with an elongate surface, along which the yam advances without substantially contacting same, the surface temperature, as described with reference to Figure 3, being above the melt point of the polymer. Unlike in the case of heating tube 20, the necessary draw force is not applied by air friction, but by the friction of the yam on yam guides 132. shown in Figure 4 is as a further modification that upon its entry into the draw zone, the yarn partially loops about several (shown are two) successively arranged yam guides 132, so that the yield point of the yarn becomes localized as a result of its heading.
As anlternative to the method shown in Figure 1, a variant of the method is shown in Figure 4, which comprises a heat treatment between godet 16 and

takeup winder 30. The fact that in the shrinkage treatment zone the yam may be advanced under very little tension permits an adjustment that makes the yam tension simultaneously suitable as takeup tension. Since otherwise the sequence of the method shown in Figure corresponds to that of Figures 1-3, the description thereof is herewith incorporated by reference.
In the variant of the method as shown in Figure 5, the yam 1 is withdrawn from the spinneret 11 not by godets, but directly by means of takeup winder 30. In this instance, the withdrawal speed is above 5,000 m/min., preferably from 6,000 to 7,500 m/min. In this process, the yam 1 is drawn simultaneously with the spinning. More particularly, the draying occurs immediately downstream of the spinneret 11 and while the hot filaments and yarn are being cocled. The drawing ceases at a point wherein the tension supplied by the winder 30 is too low to deform the cooled yam, and the heater 8 is positioned downstream of the point where drawing ceases, and upstream of the takeup winder 30. Thus during the heating operation in the heater 8, the yarn is subjected to substantially the same tension under which the yarn is withdrawn from the spinneret. This process is particularly suitable for producing without difficulty yarns which are highly susceptible to shrinkage as a result of the spin and draw method. As regards the components of the apparatus not described in this connection, refensnce may be made to the description of Figures 1 and 3.
Shown in Figure 6 is a modification of the method, which does not differ with respect to the shrinkage heat treatment from the method of Figure 4 that is herewith incorporated by reference. Once the bundle of filaments 12 is combine to yarn 1 by yarn
guide 56, the yam 1 advances to godet 21. The godet 21 being looped by yarn 1 several times withdraws

yam i from spinneret H and advances the yarn into a draw zone. In the draw zone, a heater 24 is arranged between godet 21 and godet 54, While undergoing a drawing, the yarn 1 advances over the heating surface 29 closely adjacent thereto but without substantially contacting sane. The heating surface 29 is heated to a temperature higher than the melt point bf yarn l. The tension required for the drawing is adjusted between godets 21 and 54.
It should be remarked that in all cases, the godets with guide rolls may be replaced with two or more successively arranged, driven rolls, which are looped by the yam in part in s-direction and/or Z-direction, i.e. successively in opposite direction.
This method has proven that, in particular, the sudden heat treatment at a high temperature results simultaneously in a recovery of the molecular structure of the highly partially oriented polyprcpylene yarn, so that the residual shrinkage of the yarn is reduced very substantially. In normal processes, the shrinkage free treatment, i.e. the elimination of the shrinkage tendency, acts to reduce simultaneously both the tendency to cold shrinkage and the tendency to heat shrinkage. This applies in particular to the vapor treatment methods of the prior art. The invention, i.e. a relaxation zone with a sudden heating of the yarn, permits the tendency to cold shrinkage to be selectively eliminated and, preferably, it permits the tendency to heat shrinkage to be influenced in a controlled manner.
It should be pointed out that, contrary to conventional methods, in which all godets for withdrawing, drawing, and relaxing the polypropylene yarn are heated, the godet 54 is unheated, and that it is likewise not necessary to heat godet 16.

It should be added, however, that one of the two godets S4 or 16 may also be heated, for example, to about 100'C, so as to reduce likewise the tendency to heat shrinkage in a controlled manner.
The method of the present invention can be successfully applied to standard polymers, such as polyethylene terephthalate, polytrimethylene terephthalate, polypropylene, and polyamide (preferably, PA 6 and PA 6.6, but also PA blends of different types of PA). Very good results are obtained with polypropylene with a narrow molecular weight distribution in a range smaller than 3, i;i particular with types produced on the basis of metallccene, inasmuch as these yams permit the spin-draw process, i.e. spinning and drawing in one operation and in the same zone, as is shown for example in Figure l, to be used with a heating tube.
It should be emphasized that a favorable effect can also be achieved by subjecting, the yarn to an additional vapor treatment. To this end a hot vapor nozzle 23 is provided directly at the inlet end of the heater 8, which blows hot vapor to the yam. This hot vapor condenses immediately on the not-yet heated yarn and evaporates thereafter. Duz'ing the condensation, the yam receives the corresponding amount of heat. On the other hand, the subsequent evaporation prevents a very sudden heating of the yam.-This protective treatment of the yarn could be advantageous, and will lead in any event, to a rapid reduction of the heat shrinkage. The Le-tter can be adjusted by this treatment. Likewise, t.he following sudden heat treatment at a high temperature results in a reduction of the cold shrinkage. However, the favorable effects of the present invention do not appear to require the use of the hot vappor nozzle.

The heating apparatus 9, as shown in Figures 2a-2c, consists of an elongate body or rail 114 (Figure 2c) that is provided with two longitudinal grooves 112 and is composed of a material which is heat resistant and nonscaling, and which withstands temperatures in a range above 450'C over long peripds of time without undergoing noteworthy changes. The body 114 is generally U-shaped in cross sectional configuration and includes a substantially flat base portion 116 which constitutes the heating surface 117. Connected with the base portion are three walls 118, 120, 122, between which the longitudinal grooves 112 are locared. However, it is also possible to provide base portion 116 with two or more than three upwardly directed walls, between which correspondingly more or less grooves extend. The outer walls 118 and 122 may, for example, be bolted to base portion 116. Arranged between the walls 118 and 122 and the base pprtion 116 is one heating element 124, 126 each, preferably in the form of a rod-shaped, electrical resistor, which extends over the entire length of body 114, or which may also be divided over the length into several segments, so as to enable controlled heating profiles. The heating elements 124, 126 are provided with plug contacts (not shown) for their connection to a source of current.
Center wall 120 which is located between
i
outer walls 118 and 122 and extends vertically from base portion 116, either is integral therewith, or it is connected with bottom 116 in like manaer as outer walls 118 and 122.
As an alternative, the body 114 may have a cross section similar to an extruded profile, in which the base portion 116 and walls 118, 120, 122; are made of one piece,, and which is provided in known manner with recesses, bores, bendable flaps, or the'like for receiving the heating elements.

Inserted in walls ll8, 120, 122 at regular intervals A from one another are recesses or bores 128 having substantially the sane depth, the recesses 128 arranged in center wall 120 being offset by the spacing A from the recesses 128 in side walls 118 and 122. The recesses have a circular-cylindrical shape. Each recess 128 is intersected by longitudinal grooves 112 along a secant line, so that walls 118, 120, 122 exhibit a slot 133, i.e. a rectangular oppring, facing the axial grooves 112. in the illustrated embodiment, the recesses extend perpendicularly to the groove bottom, and their depth corresponds to the height of walls 118, 120, 122, in which they are accommodated. Under certain circvimstances, it may be advantageous to incline the recesses.
Each recess 128 accommodates a yarn guide
132, the cross sectional shape of which corresponds to the cross section of the recess both in size and shape, and which, for purposes of maintaining close tolerances, rests firmly, but with a play, against the wall of the recess. The clearance between the wall of the recesses and the peripheral surface of the yam guides, as shown in the drawing, is exaggerated only for reasons of clarity. In the region of each slot
133, a portion of each yarn guide 132 extends into the axial grooves 112 such that, on opposite sides of grooves 112, successively arranged yarn guides 132 extend by a certain dimension, for example 0.1 to 1 mm, beyond a central plane extending parallal to walls 118,; 120, 122. Otherwise, the width of the slots 133 is smaller than the largest cross sectional dimension, i.e., than the diameter of yarn guides 132, so that they are unable to slide out of recesses 128.
In the illustrated embodiment, both recesses
128 and yarn guides 132 a circular-cylindrical
cross section. Other angular as well as rounded shapes, such as ellipses, diamonds, triangles, etc. are

possible. The embodiment has a fit between recesses 128 and yarn guides 132, which is kept witthin accordingly close tolerances. As a result, separate fastening means to secure yam guides 132 against axial and radial displacements are not needed, thereby eliminating special expcmses, which would otherwise result from the use of fastening means. The embodiment of Figure 2c may also have clearance or transition fits. On the one hand, these fits are narrow enough, so that the yam guides rest immovably in their recesses. On the other hand, however, the fits are also selected wide enough, so as to make it easy to pull out the yam guides from their recesses and replace or omit same.
For purposes of securing the yarn guides in the axial direction, sheet metal caps 152 ere used. To this end, side walls 118, 120, 122 are provided on their upper edge with retaining grooves 154 or a head 156, which is wider than the respective wall. In cross sectional view, the sheet metal caps 152 have a cup-shaped profile, so that in the case of center wall 120 they extend into retaining grooves 154, or that in the case of side walls 118, 122 they embrace wall head 156. otherwise, the sheet metal caps are constructed as elongate profiles, the length of which corresponds to that of the yam heater. The thickness of wall heads 156 and the position of retaining grooves 154, respectively, as well as the corresponding dimensioning of the sheet metal caps are such that the sheet metal caps secure the yarn guides in the axial, direction.
The yam guides 132 consist of materials commonly used for this purpose, such as silicon, titanium, or aluminum oxides, or of nit::ided or chromium plated steel, or the like.
Preferably in the region in which they
project from recess slot 133, the yarn guides 132 are conically beveled on their ends facing away from the

base portion 116, as is indicated at 134. As a result, the yarn guides 132 successively arranged in opposite walls lle and 120, or 122 and 120 form in the cross sectional direction of the heating apparatus 8 respectively a V-shaped groove 136, which permits to guide a yam 138 in its stretched condition between yarn guides 132, without any special auxiliary measures or arrangements between successive yarn guides 132, in a movement substantially perpendicular with respect to heating surface 112 and base portion 116. There, the yam 138 resting against the contact surfaces forms then a zigzagged yarn path.
Arranged at the ends or at several other points (see Figures 2a and 2c) of the body 114, and substantially equally spaced apart, are spacers 140, which bridge the groove 112. These yam guide elements have an upward directed yam guide surface, which serves to maintain a spacing between the yarn and the groove bottom. These rod-shaped spacers 140 are anchored in transverse bores provided in the walls 116, 120, 122.
As shown in Figure 2a, the heater 8 may
consist of two body segments 114a and 114b one
following the other in direction of the advancing yam.
While these segments differ in length, they otherwise
have the same cross sectional shape. The purpose of
such a bipartite arrangement may lie in the different
heating of heater 8 over different length segments, so
as to treat yam 138 in a heat profile which satisfies
its properties. It is also possible to use more than
the two illustrated segments. In this arrangement, it
is especially important that the angle which the two
yam heating segments form with one another, is
identically adjusted at each processing station of the spin-draw machine, so as to produce yarns of the same quality in all processing stations. To mount the two yarn heating segments a mounting support: 188 is used,

which has the length of the two heater segments. The mounting support has a U-shaped cross section. The yani heating segments are attached to the bottom of the mounting support by means of spacers 100. The dimensioning of the spacers and their position relative to the heating segment allow to define the inclination of the heating segment with respect to the straight mounting support 158. In this arrangement, the two heating segments are inclined oppositely, and form with each other an obtuse angle. Thus, mounting support 158 is used on the one hand for a specific fastening of the two heating segments, since mounting support 158 has a U-shaped profile, it embraces, however, also the two heating segments. Therefore, the mo\inting support 158 also serves to make the temperature constiant over the length and width of the heating segment». The mounting support is preferably surrotinded by an insulation.
As already indicated, rod-shaped spacers 140 may be provided, which bridge over axial groove 112 on its bottom, i.e., they extend over hieating surface 117 and define the yarn path at a specific distance spaced from the groove bottom. Alternatively or additionally, it is possible to provide a few or all yam guides 132 with a peripheral guide edge, for example, a circumferential groove 142 (Figure 2a), the height of which as measured from the groove bottom, is brought in line with the height of the. yarn path that is predetermined by spacers 140. In this manner, the yarn advancing in the groove is guided by the lateral edges of the groove. The circumferential grooves have the same depth over the circumference, i.e., they are made concentric with yarn guides 132. However, it is also possible to construct the circumferential grooves with a depth varying over the circumference, for example.in that the groove bottom is cut circular-cylindrically, but eccentrically with respect to yam guides 132. In this instance, a turning of the yarn

guides creates the possibility of finely adjusting the contact between yarn 138 and yarn guides 132, and of forming a zigzagged yarn path. This could be realized by turning the yam guides 132 jointly and to the sane extent, for example, by means of a linkage (hot shown) that interconnects the yarn guides.
The heater 8 is accommodated in an insulated box (not shown), in which it is embedded in a thermally insulated material, for example, fiber glass. The insulated box may be provided with a flap, which permits to open it, so as to provide access to heater 8, and to thread the yam. Puz±hermore, the insulated box serves with its components extending over the heater to axially secure yarn guides 132 in the body 114. To this end, the insulated box is provided with slots, which are aligned with the central plane and the bevels 134 of yarn guides 132, and which permit a yarn 138 to be treated to be inserted or threaded between the yarn guides 132. On their side walls, the slots are provided with wear-resistant insulating plates.
Likewise, if need be, the electrical contacts required for heating elements 124, 126 are accommodated in the insulated box.
As can be noted from all embodiinents, the peripheral surfaces, on which the yarn contacts the yarn guides, have a relatively large diameter. , Contrary thereto, the zigzag line, along which the yarn advances as a result of the overlap U of. sixccessive yarn guides, has a relatively small amplitude with a relatively large spacing A between two neighboring yarn guides. This allows the looping angle, at which the yam loops about the yam guides or the contact surfaces formed on same, to be small whan summed.
In the embodiment of Figure 2b, the heating rail is provided on its side facing away from axial groove 112 with two grooves, which extend substantially below respective ones of the yam guide grooves 112.

Inserted into these grooves are the heating elements 124 and 12C. The heating elements are clamped in place by mounting plate 159, which extends over the entire length of the yam heater. To this end, the mounting plate is likewise provided with grooves, which surround heating elements 124, 12C. By detaching the mounting plate 159, the heating elements 124, 126 can easily be exchanged.
The distance of the yarn from heating, surface 117 is very small. The distance is in a range from 0.5 to 5 mm. Preferably, the upper value is no more than 3.5 mm, so as to realize a satisfactory transfer of heat and an exact, trouble-free temperature control. For reasons of practicability, the lower limit value is 0.5 mm. As a result, at a correspondingly high temperature of the heating rail of more than 350'C, the yam undergoes a sudden heating. The yarn guides 132 may also be left out at least in part, or they may be removed, should they have a negative effect. On the one hand, they contribute to smoothing the yam, but they barely serve to heat the yarn as it advances in contact therewith. On the other hand, the yarn guides exert only little friction on the yarn, because of its small looping. Importantly, however, is the noncontacting advance of the yarn closely adjacent to the highly heated heating surface.
As an alternative to the heater i as illustrated in Figures 2a-2c, the heater for reducing the shrinkage tendency may take the form of an externally heated tube, through which the yarn advances without significant contact between the advancing yarn and the tube. The tube will provide a satisfactory uniform control of the heat and it may b« slotted to facilitate thread-up of the yarn.
In the drawings and the specification, there has been set forth preferred embodiments of the invention, and, although specific terms are employed,

the terms are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.




Tne presenr invention relates to a method and an apparatus for spinning, drawing, and winding a synthetic multi-filament yarn.
U.S. Patent No. 4,123,492 discloses a method and apparatus for the spinning, drawing, and winding of a synthetic multi-filament yarn in a single, continuous process. In such process, the yam tends to shrink, i.e., to shorten, in the package, thereby subjecting the wound yam to a very high tension which can. lead to the destruction of the package. The problem is especially serious in the winding of both nylon 6 and nylon 6.6 (polyamide) yams, and polypropylene yarns. It is therefore necessary to subject the yarn to a shrinkage treatment before winding, so as to remove its tendency to shrink. However, this additional procedure is undesirable for textile technological reasons, including the fact that the tendency of the yarn to shrink from heat is useful in many subsequent processing operations.
It is an object of the present invention to provide a method and apparatus for spinning a synthetic multi-filament yam which includes a shrinkage treatment which removes the tendency of the yarn to shrink in the package, yet does not significantly effect the tendency to shrinkage which is caused in particular by a heat treatment or by boiling, and which

is desirable and favorable in subsequent processing operations.
It is a more particular object of the present invention to provide a method and apparatus of the described type which includes a treatment which reduces the so-called package shrinkage, i.e., the tendency to cold shrinkage, to a harmless degree, without significantly effecting the hot shrinkage tendency which is useful in many subsequent processing operations.
Summary of the Invention
The above and other objects and advantages of the present invention are achieved by the provision of a method and apparatus which includes the steps of extruding a polymeric melt to form a plurality of advancing filaments, and gathering the filaments to form an advancing yarn. The advancing yarn is then subjected to a drawing operation, and thereafter the advancing yam is heated by guiding the advancing yarn . along a path of travel which is adjacent but at least essentially spaced from an elongate heating surface. The heating surface is heated to a temperature which is above the melting temperature of the yarn, and during such heating the advancing yarn is subjected to a tension which is insufficient to cause a plastic deformation of the yarn. Finally, the advancing yarn is wound into a package.
Preferably, the temperature of the heating surface is more than about 100'C above the melting temperature of the yarn, and most preferably, the temperature is between about 200 and 300C: above the melting temperature of the yarn.
During the heating step, the yarn is subjected to tension which is not greter than about 0.3 cN/dtex during the heating step, and preferably.

the tension is between about 0. 1 and 0.2 cN/'dtex during the heating step.
The resulting yarn has a hot shrinkage tendency which is greater than about 3%, and the tendency is preferably more than 20%, and most preferably it is between about 30% and about 40%.
An advantage of the present invention is that the textile technological properties of the yarn are not adversely affected by the shrinkage exeatment of the invention. In particular, after unwinding, the yam may still exhibit a high hot shrinkage tendency, which is expressed, for example, as boiling shrinkage. Also, the feed rolls or feed systems, which advance the yarn into the shrinkage treatment zone or withdraw it therefrom, need not be heated. This is not only a substantial simplification of mechanical engineering, but also permits a more favorable control of the process. During the treatment, the yarn is subjected only to a yarn tension which is lower than the tension required for drawing the already oriented yarn. In the case of polyamide, polyester or polytrimethylene terephthalate yams, the temperature of the heating surface is preferably higher than 350C, in the case of polypropylene yarns the surface teniperature is preferably higher than 200C.
The present invention permits that yarn to advance in the spin zone and/or shrinkage zone and/or takeup zone under very little tension, without incurring the risk of an unsteady threadline or the formation of laps on the godet or another disturbance of the process.
In the preferred embodiment, the yarn is guided along the heating surface by one or more short guides which are distributed along the surface. This
serves the purpose of guiding the yarn at a precisely
defined distance from the heated surface. A distance
from 0.5 to 3.5 mm is desirable.

AS noted above, it is possible to advance the yam in the shrinkage treatment zone under very little tension. This permits the process to be simplified, in that the yarn tension is adjusted such that it is simultaneously suitable for winding.
In one embodiment, the heat, treatment occurs between two yam feeding godets. This provides an advantage in that it is possible to edjunt the yam tension very uniformly and, thus, the shrinkage in a very controlled manner.
In the short spinning process, the yams being produced are very susceptible to shi-inkage, and they present great problems during the takeup. In this instance, it will be advantageous Co utilize an embodiment of the invention wherein the yarn is advanced directly from the spin box to the take-up winder without the use of yam feeding godets, and at a withdrawal speed which is greater than 5000 m/min, and preferably between 6000 and 7500 m/min.
The method of the present invention is suitable for all polymers in use. It allows to produce a high-quality package of polyester yarn yh;.ch has still a hot or boiling shrinkage ol! rrore them 20% after unwinding.
Especially important is the shrinkage-free treatment for polyamides. The currtently conducted shrinkage-free treatments, in particular with vapor, result in an overall reduction of the snrinkage tendency- While the method of the present invention permits removal only of the shrinkage in the package, the shrinkage tendency remains unslrif.ngei when heat is supplied, or it remains adjustablt by other parameters of the process control.
This applies in like manner to polypropylene yams, which present in the conventional process significant-problems daring winding.

An especially advantageous method of drawing in accordance with one embodiment of. the present invention includes withdrawing the yarn from the spinneret by means of a godet at a high speed of more than 3,500 m/min. and advancing same through a narrow heating tube, in the heating tube, the yam undergoes drawing as a result of tension and heating. Until now, this method has been impractical for materials with a strong shrinkage tendency, in particular nylon and polypropylene, since by this kind of drawing the yams are imparted a high tendency to shrinkage in the package. However, the combination with the method of the present invention allows this draw method to be applied to all types of materials.
Prior to the heat treatment, the yarn may be subjected to a drawing operation wherein the yarn is guided closely adjacent, but at least essentially spaced from an elongate heater which is neated to a temperature higher than the melt point of the yarn, preferably from 100' to 300C above the melt point, and the yam is tensioned to an extent leading to a plastic deformation of the yarn. Despite the low yjarn tension in the draw zone, the yam forms a precisely localized yield point and can be totally drawn. For the formation of a precisely established yield point, the method may be further improved by grinding the advancing yarn over guides, while partially looping the same, before entering into the draw zone.
A further, advantageous variant of the method for the spinning includes withdrawing the yarn from the spinneret at a speed of more than 500 m/min, and so as to result in the simultaneous drawing of the yarn, as is known from EP 0 539 866 A2.
The apparatus of the present invention distinguishes itself in that despite the very high yarn speeds, the heating surface is very short, in; particular, in a range from 300 to 1000 mm.

The heater of the present invention may take the form of a generally U-shaped body or rail, which defines a longitudinal heating surface in a groove thereof and with the yarn being guided to have essentially no contact with the heating surface. This construction permits a simple operation and, in particular, a simple selection of the distance at which the yam advances from the heated surface. In this embodiment, this distance may be predetermined by yarn guides as a function of the yam material, the denier, the number of filaments, the yarn speed, and the adjusted temperature of the heating surface.
The body or rail of the heater may comprise two separate body segments which are positioned in an end to end relationship, and which have separate temperature controls. Besides a smooth advance of the yarn, this embodiment allows in particular a stepped temperature control that is adapted to the process. For example, a first step is controlled in a temperature range from 450 to 550C, and the second step in a temperature range from 400 to 500C.
The invention applies to all polyamides, polyester, as well as polytrimethylene terephthalate (PTT). In the case of polypropylene, the temperatures are correspondingly lower, preferably by 100C to 200'C.
A combination of the invention which is especially favorable in terms of process er.ginefering, utilizes in the draw zone a narrow tube surrounding the threadline, into which the yarn advancing from the spinneret enters without passing over a godet. This simple solution of mechanical engineering becomes possible for all materials only as a result of this invention. Where the yam is withdrawn from the spinning zone by means of an unheated godet or the like, and advanced to the draw zone, the invention requires no special measures to reduce the shrinkage

tendency of the yarn already in the draw zone. Thus, additional possibilities of adjustment are obtained, so as to modify the other yam properties, in particular, tensile strength and elongation. It is possible to spin in particular highly oriented or fully oriented yams in a continuous process.
Important advantages result from the shrinkage treatment. The invention allows the so-called "package shrinkage", i.e. the tendency to cold shrinkage, to be reduced to a harmless degree, or to be eliminated, without thereby adversely effecting the hot shrinkage tendency, i.e., boiling shrinkage or hot air shrinkage. From the viewpoint of textile or technology, it is not desirable to adjust the hot shrinkage tendency to the requirements of winding, but to the requirements of subsequent processing operations. Thus, for example, a certain shrinkage tendency is desired in a sewing yam, so that the seam can adjust itself to the shrinkage of the fabric. When employing the yam for hosiery, the leg shape is obtained, in that the untreated hose is pulled over a flat board and adjusts itself to same by heat treatment and shrinkage. In other fabrics, such as corduroy, shrinkage causes the density to increase. In all these cases, the requirement for shrinkage-free winding in accordance with the invention has no disturbing influence on the tendency to heat shrinkage that is to be achieved.
Accordingly the present invention provides a method of spinning a synthetic multi-filament yam comprising the steps of extmding a polymeric melt to form a plurality of advancing filaments, and gathering the filaments to form an advancing yam, drawing the advancing yam, and thereafter

heating the advancing yam by guiding the advancing yam along a path of travel which is adjacent but at least essentially spaced from an elongate heating surface, with the heating surface being heated to a temperature which is above the melting temperature of the yam, and while subjecting the advancing yam to a tension which is insufficient to cause a plastic deformation of the yam, and then winding the advancing yam into a package.
Accordingly the present invention also provides an apparatus for spinning a synthetic multi-filament yam as herein-above described, said apparatus comprising means for extruding a polymeric melt to fomi a plurality of advancing filaments, and gathering the filaments to form an advancing multi-filament yam, means for drawing the advancing yam and so as to define a drawing zone, means defining a draw-free zone downstream of said drawing zone and wherein the advancing yam is subjected to a tension insufficient for drawing of the yam, a heater positioned within the draw-free zone and comprising an elongate heating surface, and means for heating the heating surface to a temperature which is above the melting temperature of the yarn, and a winder positioned downstream of said heater for winding the advancing yam into a package.
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, taken in conjunction with the accompanying drawings, in which:
Figure 1 is a schematic view of the spinning process and the essential elements of an apparatus which embody the present invention;

Figures 2a-2c illustrate an embodiment of a heating apparatus for use with the invention;
Figure 3 is a schematic view of a modified spinning process and apparatus which embodies the invention;
Figure 4 is a schematic view of a further modified spinning process and apparatus which embodies the invention;
Figure 5 is a schematic view of another modified spinning process and apparatus which embodies the invention; and
Figure 6 is a schematic view of; still another modified spinning process and apparatus which embodies the invention.
Detailed Description of the Preferred Embodiments Referring more particularly to the drawings. Figure 1 illustrates a melt spinning apparatus wherein a yarn 1 is spun from a thermoplastic material. The thermoplastic material is supplied through a hopper 2 to an extruder 3, The extruder 3 is driwen by a motor 4, which is controlled by a control unit 49. in the extruder 3, the thermoplastic material is melted. The work of deformation (shearing energy), which is applied by the extruder 3 to the material, assists in the melting process. In addition, a heater, for example in the form of a resistance heater 5, is provided, which is controlled by a heating control unit SO. Through a melt line 6, which includes a pressure sensor 7 for measuring the melt pressure so as to control the pressure and speed of extruder 3, the melt reaches a gear pump 9, which is driven by a pump motor 44.' The pump motor 44 is controlled by a control unit 45, so as to permit a very fine adjustment of the pump speed. The pump 9 transports the melt to a heated spin box 10, the underside of which mounts a spinneret lA. From the, spinneret ll, the melt emerges in the form of fine

strands of filaments 12. The filament strands advance through a cooling shaft 15. In the cooling shaft 15, an air current is directed crosswise or radially to the web of filaments 12, thereby cooling the filaments.
At the outlet end of cooling shaft 15, the web of filaments is combined to form the yarn 1. The yarn is withdrawn from the cooling shaft 15 and from spinneret 11 by a godet 54. The yarn loops several times about godet 54. To this end a guide roll 55 is used, which is axially inclined relative to the godet 54. The guide roll 55 is freely rotatable. The godet 54 is driven by a motor at a preadjustable speed. This withdrawal speed is by a multiple higher than the natural exit speed of the filaments 12 from the spinneret, thereby subjecting the yarn to a very high tension, which leads to its drawing. The drawing is assisted by a heating tube 20 which defines a draw heating zone 31. The heating tube 20 measures, for example, 1.150 m long. It is heated to a temperature, which is for polyester and PTT from 140' to 180'C, for polypropylene from 100 to 150C, and for polyamide from 140' to 220'C. The yield point of the yam is located in an inlet region of this heating tube. The temperature control in the further extension of the heating tube permits the properties of the yarn, such as its strength, boiling shrinkage, and elongation, to be adjusted. Such a heating tube is described, for example, in DE 38 08 854, which corresponds to U.S. Patent No. 4,902,461, and also in DE 37 20 337.
The godet 54 is followed by a second godet 16 with a guide roll 17, before the yarn 1 is wound in a takeup 30 to a package 33.
Arranged between godets 54 and 16 is a heater a in accordance with the invention. The heater 8 is an elongate body or rail a long which the yarn advances slightly spaced apart therefrom. This elongate heater is divided into several segments, namely a first

heating zone 27 and a second heating zone 38 as illustrated, which may be heated independently of each other, as is described in more detail below.
From godet 16 of Figure 1 or Figure 3, the yam 1 advances to a so-called "apex yarn guide" 25 and thence to a traversing triangle 26. Not shown in Figure 1 is the traversing mechanism, which comprises two oppositely rotating blades that reciprocate the. yam 1 over the length of package 33. In so doing, the yam loops about a contact roll (not shown) downstream of the yam traversing mechanism. The contact roll lies against the surface of package 33. It serves to measure the surface speed of package 33, which is formed on a tube 35. The tube 35 Is clamped on a winding spindle 34. The winding spindle 34 is driven by a motor and a control unit such that the surface speed of package 33 remains constant. To this end and for use as a control variable, the speed of the freely rotatable contact roll is sensed.
It should be noted that the yam traversing mechanism may also be a standard cross-spiralled roll with a yam guide traversing in the cross-spiralled groove.
In one embodiment, a polypropylene yam with a filament denier from 0.7 to 3 dtex is spun and withdrawn from the spinneret 11 by godet 54 and at a speed higher than 3,500 and 4,500 m/min,, the yam being subjected to a sudden heating in heater 8. The godet 16 has a circumferential speed, which is not higher than that of godet 54. Thus, the yarn is not drawn/ and it is essentially relaxed as it passes through the heater, in this embodiment, the heater is operated at very high temperatures above the melting point, i.e., substantially above 220'C. The first zone 27 of the elongate heater is heated to 330'C and the second zone 28 to 150C.This allows as acequate relaxation treatment between godets 16 and 54 to be

achieved, which continues even into the takeup zone. Preferably, the temperatures of the first heating zone 27 are somewhat higher than those of the second heating zone 28, nanely in a preferred range from 250* to 550C. The temperature of the second heading zone 29 is preferably from 150 to 450'C. The yarn tension between godets 54 and 16 can be adjusted to less than 0.1 cN/dtex, taking into account the speed difference and the shrinkage forces. This range is especially advantageous for activating or eliminating the tendency to cold shrinkage. The temperature control, in particular in the second heating zone 28, permits the hot shrinkage tendency to also be influenced in a controlled manner, without thereby adversely affecting the cold shrinkage tendency that is detrimental to winding.
A further godet 21 and guide zoll 22 may be arranged upstream of godet 54, as is shown in Figure 3. In this instance, a subsequent drawing occurs between these godets 21 and 54. To this end, the speed of godet 54 is adjusted higher than the speed of godet 21. A tension is applied, which leads to a further

deformation of the yarn I. Preferably, a further heat treatment also occurs between these two godets. To this end, a heater 24 is shown in Figure 3. The heater has a heating surface 29 that faces the yarn 1. The yarn 1 advances therealong without contacting, but closely adjacent this heated surface 29, at: a distance from 0.5 to 5 mm. The surface temperature is adjusted higher than the melting point of the particular polymer. This subsequent drawing and the sudden heating provided therein allow to achieve an influencing of the crystal structure in the meaning of a greater long-term stability of the yam. As a result, the effectiveness of the subsequent treatment

between godets 54 and 16 is amplified, and the pacJcage shrinkage and the tendency to shrink on the package are further reduced.
It should be noted that otherwise the method shown in Figure 3 corresponds to that described above with respect to Figure 1. When the methods of Figures 1 and 3 are employed, it is possible to wind subsequently both soft and especially shrinkage-sensitive, hard packages, which will not exhibit a detrimental package shrinkage with damage or destruction of the package, even in their long-term behavior. Both methods are carried out in that the yam is withdrawn from the spinneret H at a very high speed of more than 3,500 m/min by means of godet 54 in the instance of Figure 1, and by means of godet 21 in the instance of Figure 3. In the case of Figure 3, the subsequent drawing may amount to another 10 to 30%.
The modification of the crystalline structure and the increase of the length stability, as provided by the process of Figure 3, may also be produced in a method as shown in Figure l, in that the heating tube 20 in the draw heating zone 31 is replaced, as shown in Figure 4, with an elongate surface, along which the yam advances without substantially contacting same, the surface temperature, as described with reference to Figure 3, being above the melt point of the polymer. Unlike in the case of heating tube 20, the necessary draw force is not applied by air friction, but by the friction of the yam on yam guides 132. shown in Figure 4 is as a further modification that upon its entry into the draw zone, the yarn partially loops about several (shown are two) successively arranged yam guides 132, so that the yield point of the yarn becomes localized as a result of its heading.
As anlternative to the method shown in Figure 1, a variant of the method is shown in Figure 4, which comprises a heat treatment between godet 16 and

takeup winder 30. The fact that in the shrinkage treatment zone the yam may be advanced under very little tension permits an adjustment that makes the yam tension simultaneously suitable as takeup tension. Since otherwise the sequence of the method shown in Figure corresponds to that of Figures 1-3, the description thereof is herewith incorporated by reference.
In the variant of the method as shown in Figure 5, the yam 1 is withdrawn from the spinneret 11 not by godets, but directly by means of takeup winder 30. In this instance, the withdrawal speed is above 5,000 m/min., preferably from 6,000 to 7,500 m/min. In this process, the yam 1 is drawn simultaneously with the spinning. More particularly, the draying occurs immediately downstream of the spinneret 11 and while the hot filaments and yarn are being cocled. The drawing ceases at a point wherein the tension supplied by the winder 30 is too low to deform the cooled yam, and the heater 8 is positioned downstream of the point where drawing ceases, and upstream of the takeup winder 30. Thus during the heating operation in the heater 8, the yarn is subjected to substantially the same tension under which the yarn is withdrawn from the spinneret. This process is particularly suitable for producing without difficulty yarns which are highly susceptible to shrinkage as a result of the spin and draw method. As regards the components of the apparatus not described in this connection, refensnce may be made to the description of Figures 1 and 3.
Shown in Figure 6 is a modification of the method, which does not differ with respect to the shrinkage heat treatment from the method of Figure 4 that is herewith incorporated by reference. Once the bundle of filaments 12 is combine to yarn 1 by yarn
guide 56, the yam 1 advances to godet 21. The godet 21 being looped by yarn 1 several times withdraws

yam i from spinneret H and advances the yarn into a draw zone. In the draw zone, a heater 24 is arranged between godet 21 and godet 54, While undergoing a drawing, the yarn 1 advances over the heating surface 29 closely adjacent thereto but without substantially contacting sane. The heating surface 29 is heated to a temperature higher than the melt point bf yarn l. The tension required for the drawing is adjusted between godets 21 and 54.
It should be remarked that in all cases, the godets with guide rolls may be replaced with two or more successively arranged, driven rolls, which are looped by the yam in part in s-direction and/or Z-direction, i.e. successively in opposite direction.
This method has proven that, in particular, the sudden heat treatment at a high temperature results simultaneously in a recovery of the molecular structure of the highly partially oriented polyprcpylene yarn, so that the residual shrinkage of the yarn is reduced very substantially. In normal processes, the shrinkage free treatment, i.e. the elimination of the shrinkage tendency, acts to reduce simultaneously both the tendency to cold shrinkage and the tendency to heat shrinkage. This applies in particular to the vapor treatment methods of the prior art. The invention, i.e. a relaxation zone with a sudden heating of the yarn, permits the tendency to cold shrinkage to be selectively eliminated and, preferably, it permits the tendency to heat shrinkage to be influenced in a controlled manner.
It should be pointed out that, contrary to conventional methods, in which all godets for withdrawing, drawing, and relaxing the polypropylene yarn are heated, the godet 54 is unheated, and that it is likewise not necessary to heat godet 16.

It should be added, however, that one of the two godets S4 or 16 may also be heated, for example, to about 100'C, so as to reduce likewise the tendency to heat shrinkage in a controlled manner.
The method of the present invention can be successfully applied to standard polymers, such as polyethylene terephthalate, polytrimethylene terephthalate, polypropylene, and polyamide (preferably, PA 6 and PA 6.6, but also PA blends of different types of PA). Very good results are obtained with polypropylene with a narrow molecular weight distribution in a range smaller than 3, i;i particular with types produced on the basis of metallccene, inasmuch as these yams permit the spin-draw process, i.e. spinning and drawing in one operation and in the same zone, as is shown for example in Figure l, to be used with a heating tube.
It should be emphasized that a favorable effect can also be achieved by subjecting, the yarn to an additional vapor treatment. To this end a hot vapor nozzle 23 is provided directly at the inlet end of the heater 8, which blows hot vapor to the yam. This hot vapor condenses immediately on the not-yet heated yarn and evaporates thereafter. Duz'ing the condensation, the yam receives the corresponding amount of heat. On the other hand, the subsequent evaporation prevents a very sudden heating of the yam.-This protective treatment of the yarn could be advantageous, and will lead in any event, to a rapid reduction of the heat shrinkage. The Le-tter can be adjusted by this treatment. Likewise, t.he following sudden heat treatment at a high temperature results in a reduction of the cold shrinkage. However, the favorable effects of the present invention do not appear to require the use of the hot vappor nozzle.

The heating apparatus 9, as shown in Figures 2a-2c, consists of an elongate body or rail 114 (Figure 2c) that is provided with two longitudinal grooves 112 and is composed of a material which is heat resistant and nonscaling, and which withstands temperatures in a range above 450'C over long peripds of time without undergoing noteworthy changes. The body 114 is generally U-shaped in cross sectional configuration and includes a substantially flat base portion 116 which constitutes the heating surface 117. Connected with the base portion are three walls 118, 120, 122, between which the longitudinal grooves 112 are locared. However, it is also possible to provide base portion 116 with two or more than three upwardly directed walls, between which correspondingly more or less grooves extend. The outer walls 118 and 122 may, for example, be bolted to base portion 116. Arranged between the walls 118 and 122 and the base pprtion 116 is one heating element 124, 126 each, preferably in the form of a rod-shaped, electrical resistor, which extends over the entire length of body 114, or which may also be divided over the length into several segments, so as to enable controlled heating profiles. The heating elements 124, 126 are provided with plug contacts (not shown) for their connection to a source of current.
Center wall 120 which is located between
i
outer walls 118 and 122 and extends vertically from base portion 116, either is integral therewith, or it is connected with bottom 116 in like manaer as outer walls 118 and 122.
As an alternative, the body 114 may have a cross section similar to an extruded profile, in which the base portion 116 and walls 118, 120, 122; are made of one piece,, and which is provided in known manner with recesses, bores, bendable flaps, or the'like for receiving the heating elements.

Inserted in walls ll8, 120, 122 at regular intervals A from one another are recesses or bores 128 having substantially the sane depth, the recesses 128 arranged in center wall 120 being offset by the spacing A from the recesses 128 in side walls 118 and 122. The recesses have a circular-cylindrical shape. Each recess 128 is intersected by longitudinal grooves 112 along a secant line, so that walls 118, 120, 122 exhibit a slot 133, i.e. a rectangular oppring, facing the axial grooves 112. in the illustrated embodiment, the recesses extend perpendicularly to the groove bottom, and their depth corresponds to the height of walls 118, 120, 122, in which they are accommodated. Under certain circvimstances, it may be advantageous to incline the recesses.
Each recess 128 accommodates a yarn guide
132, the cross sectional shape of which corresponds to the cross section of the recess both in size and shape, and which, for purposes of maintaining close tolerances, rests firmly, but with a play, against the wall of the recess. The clearance between the wall of the recesses and the peripheral surface of the yam guides, as shown in the drawing, is exaggerated only for reasons of clarity. In the region of each slot
133, a portion of each yarn guide 132 extends into the axial grooves 112 such that, on opposite sides of grooves 112, successively arranged yarn guides 132 extend by a certain dimension, for example 0.1 to 1 mm, beyond a central plane extending parallal to walls 118,; 120, 122. Otherwise, the width of the slots 133 is smaller than the largest cross sectional dimension, i.e., than the diameter of yarn guides 132, so that they are unable to slide out of recesses 128.
In the illustrated embodiment, both recesses
128 and yarn guides 132 a circular-cylindrical
cross section. Other angular as well as rounded shapes, such as ellipses, diamonds, triangles, etc. are

possible. The embodiment has a fit between recesses 128 and yarn guides 132, which is kept witthin accordingly close tolerances. As a result, separate fastening means to secure yam guides 132 against axial and radial displacements are not needed, thereby eliminating special expcmses, which would otherwise result from the use of fastening means. The embodiment of Figure 2c may also have clearance or transition fits. On the one hand, these fits are narrow enough, so that the yam guides rest immovably in their recesses. On the other hand, however, the fits are also selected wide enough, so as to make it easy to pull out the yam guides from their recesses and replace or omit same.
For purposes of securing the yarn guides in the axial direction, sheet metal caps 152 ere used. To this end, side walls 118, 120, 122 are provided on their upper edge with retaining grooves 154 or a head 156, which is wider than the respective wall. In cross sectional view, the sheet metal caps 152 have a cup-shaped profile, so that in the case of center wall 120 they extend into retaining grooves 154, or that in the case of side walls 118, 122 they embrace wall head 156. otherwise, the sheet metal caps are constructed as elongate profiles, the length of which corresponds to that of the yam heater. The thickness of wall heads 156 and the position of retaining grooves 154, respectively, as well as the corresponding dimensioning of the sheet metal caps are such that the sheet metal caps secure the yarn guides in the axial, direction.
The yam guides 132 consist of materials commonly used for this purpose, such as silicon, titanium, or aluminum oxides, or of nit::ided or chromium plated steel, or the like.
Preferably in the region in which they
project from recess slot 133, the yarn guides 132 are conically beveled on their ends facing away from the

base portion 116, as is indicated at 134. As a result, the yarn guides 132 successively arranged in opposite walls lle and 120, or 122 and 120 form in the cross sectional direction of the heating apparatus 8 respectively a V-shaped groove 136, which permits to guide a yam 138 in its stretched condition between yarn guides 132, without any special auxiliary measures or arrangements between successive yarn guides 132, in a movement substantially perpendicular with respect to heating surface 112 and base portion 116. There, the yam 138 resting against the contact surfaces forms then a zigzagged yarn path.
Arranged at the ends or at several other points (see Figures 2a and 2c) of the body 114, and substantially equally spaced apart, are spacers 140, which bridge the groove 112. These yam guide elements have an upward directed yam guide surface, which serves to maintain a spacing between the yarn and the groove bottom. These rod-shaped spacers 140 are anchored in transverse bores provided in the walls 116, 120, 122.
As shown in Figure 2a, the heater 8 may
consist of two body segments 114a and 114b one
following the other in direction of the advancing yam.
While these segments differ in length, they otherwise
have the same cross sectional shape. The purpose of
such a bipartite arrangement may lie in the different
heating of heater 8 over different length segments, so
as to treat yam 138 in a heat profile which satisfies
its properties. It is also possible to use more than
the two illustrated segments. In this arrangement, it
is especially important that the angle which the two
yam heating segments form with one another, is
identically adjusted at each processing station of the spin-draw machine, so as to produce yarns of the same quality in all processing stations. To mount the two yarn heating segments a mounting support: 188 is used,

which has the length of the two heater segments. The mounting support has a U-shaped cross section. The yani heating segments are attached to the bottom of the mounting support by means of spacers 100. The dimensioning of the spacers and their position relative to the heating segment allow to define the inclination of the heating segment with respect to the straight mounting support 158. In this arrangement, the two heating segments are inclined oppositely, and form with each other an obtuse angle. Thus, mounting support 158 is used on the one hand for a specific fastening of the two heating segments, since mounting support 158 has a U-shaped profile, it embraces, however, also the two heating segments. Therefore, the mo\inting support 158 also serves to make the temperature constiant over the length and width of the heating segment». The mounting support is preferably surrotinded by an insulation.
As already indicated, rod-shaped spacers 140 may be provided, which bridge over axial groove 112 on its bottom, i.e., they extend over hieating surface 117 and define the yarn path at a specific distance spaced from the groove bottom. Alternatively or additionally, it is possible to provide a few or all yam guides 132 with a peripheral guide edge, for example, a circumferential groove 142 (Figure 2a), the height of which as measured from the groove bottom, is brought in line with the height of the. yarn path that is predetermined by spacers 140. In this manner, the yarn advancing in the groove is guided by the lateral edges of the groove. The circumferential grooves have the same depth over the circumference, i.e., they are made concentric with yarn guides 132. However, it is also possible to construct the circumferential grooves with a depth varying over the circumference, for example.in that the groove bottom is cut circular-cylindrically, but eccentrically with respect to yam guides 132. In this instance, a turning of the yarn

guides creates the possibility of finely adjusting the contact between yarn 138 and yarn guides 132, and of forming a zigzagged yarn path. This could be realized by turning the yam guides 132 jointly and to the sane extent, for example, by means of a linkage (hot shown) that interconnects the yarn guides.
The heater 8 is accommodated in an insulated box (not shown), in which it is embedded in a thermally insulated material, for example, fiber glass. The insulated box may be provided with a flap, which permits to open it, so as to provide access to heater 8, and to thread the yam. Puz±hermore, the insulated box serves with its components extending over the heater to axially secure yarn guides 132 in the body 114. To this end, the insulated box is provided with slots, which are aligned with the central plane and the bevels 134 of yarn guides 132, and which permit a yarn 138 to be treated to be inserted or threaded between the yarn guides 132. On their side walls, the slots are provided with wear-resistant insulating plates.
Likewise, if need be, the electrical contacts required for heating elements 124, 126 are accommodated in the insulated box.
As can be noted from all embodiinents, the peripheral surfaces, on which the yarn contacts the yarn guides, have a relatively large diameter. , Contrary thereto, the zigzag line, along which the yarn advances as a result of the overlap U of. sixccessive yarn guides, has a relatively small amplitude with a relatively large spacing A between two neighboring yarn guides. This allows the looping angle, at which the yam loops about the yam guides or the contact surfaces formed on same, to be small whan summed.
In the embodiment of Figure 2b, the heating rail is provided on its side facing away from axial groove 112 with two grooves, which extend substantially below respective ones of the yam guide grooves 112.

Inserted into these grooves are the heating elements 124 and 12C. The heating elements are clamped in place by mounting plate 159, which extends over the entire length of the yam heater. To this end, the mounting plate is likewise provided with grooves, which surround heating elements 124, 12C. By detaching the mounting plate 159, the heating elements 124, 126 can easily be exchanged.
The distance of the yarn from heating, surface 117 is very small. The distance is in a range from 0.5 to 5 mm. Preferably, the upper value is no more than 3.5 mm, so as to realize a satisfactory transfer of heat and an exact, trouble-free temperature control. For reasons of practicability, the lower limit value is 0.5 mm. As a result, at a correspondingly high temperature of the heating rail of more than 350'C, the yam undergoes a sudden heating. The yarn guides 132 may also be left out at least in part, or they may be removed, should they have a negative effect. On the one hand, they contribute to smoothing the yam, but they barely serve to heat the yarn as it advances in contact therewith. On the other hand, the yarn guides exert only little friction on the yarn, because of its small looping. Importantly, however, is the noncontacting advance of the yarn closely adjacent to the highly heated heating surface.
As an alternative to the heater i as illustrated in Figures 2a-2c, the heater for reducing the shrinkage tendency may take the form of an externally heated tube, through which the yarn advances without significant contact between the advancing yarn and the tube. The tube will provide a satisfactory uniform control of the heat and it may b« slotted to facilitate thread-up of the yarn.
In the drawings and the specification, there has been set forth preferred embodiments of the invention, and, although specific terms are employed,

the terms are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.

Documents:

0129-mas-1996 others.pdf

0129-mas-1996 abstract.jpg

0129-mas-1996 abstract.pdf

0129-mas-1996 claims.pdf

0129-mas-1996 correspondence others.pdf

0129-mas-1996 correspondence po.pdf

0129-mas-1996 description (complete).pdf

0129-mas-1996 drawings.pdf

0129-mas-1996 form-1.pdf

0129-mas-1996 form-26.pdf

0129-mas-1996 form-4.pdf

0129-mas-1996 petition.pdf


Patent Number 193789
Indian Patent Application Number 129/MAS/1996
PG Journal Number 02/2006
Publication Date 13-Jan-2006
Grant Date 28-Nov-2005
Date of Filing 25-Jan-1996
Name of Patentee M/S. BARMAG AG
Applicant Address LEVERKUSER STRASSE 65, 42897 REMSCHEID
Inventors:
# Inventor's Name Inventor's Address
1 HEINZ SCHIPPERS SENNEKWEUSTRASSE 14, 42897 REMSCHEID
2 RAHIM GROB SS MOZARTSTRABE 17, 42929 WERMELSKIRCHEN,
PCT International Classification Number D01D5/16
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 195 26 106.2 1995-07-18 Denmark
2 195 42 699.1 1995-11-16 Denmark
3 195 06 369.4 1995-02-23 Denmark
4 195 30 818.2 1995-08-23 Denmark