DESC:FIELD
The present disclosure relates to an apparatus and a process for preparation of a texturized yarn.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.
Heat memorable yarn refers to a heat treated yarn having multiple lengthwise segments varying in molecular chain orientation and crystallinity.
Godet Roller refers to a roller for guiding synthetic filaments during drawing.
mpm refer to miles per minute, which is a unit for the surface speed of the object.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A fabric can be improved aesthetically by imparting texture. However, the production of such fabric requires knitting and weaving two or more colored yarn and multiple feeder units. Variable dye shades can be obtained by dyeing techniques such as sectional dyeing which is tedious and costly. The conventional means do not provide any single one-bath dyeing process which can produce lengthwise segments having variable texture and/or dye shade.
Hence, there is felt a need for a simple process for producing fabric with variable texture and/or dye shade which mitigates the above mentioned limitations.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a simple apparatus for preparing a textured yarn.
Still another object of the present disclosure is to provide a simple process for preparing a textured yarn having lengthwise variation in texture and/or dye shade.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
In one aspect, the present disclosure provides an apparatus for preparing the texturized yarn. The apparatus comprises:
• a plurality of sequential godet rollers, wherein at least one of the plurality of sequential godet rollers is a modified godet roller, wherein the modified godet roller comprises a plurality of contacting segments and a plurality of non-contacting segments on the exterior surface of the modified godet roller;
• at least one driving means connected to the plurality of sequential godet rollers, wherein the at least one driving means is configured to spin each of the plurality of sequential godet rollers around its axis; and
• a heating means coupled to the modified godet roller for heating the modified godet roller.
The apparatus further comprises a unit for combining the texturized filaments.
In another aspect, the present disclosure provides a process for preparing a texturized yarn. The process comprises obtaining filaments by melt-spinning of a polymer; spinning the filaments onto a plurality of sequential godet rollers, characterized in that at least one godet roller is a modified godet roller, to obtain a plurality of texturized filaments varying in the bulk density along its length and combining the plurality of texturized filaments to obtain the texturized yarn.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The texturized yarn of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1(A) illustrates a spinning apparatus comprising two godet rollers (102) and modified godet roller (104), in accordance with an embodiment the present disclosure;
Figure 1(B) illustrates a spinning apparatus of Figure 1(A) wherein a godet roller (102) is replaced by modified godet roller (104), in accordance with another embodiment of the present disclosure;
Figure 2 illustrates the shape of the modified godet roller (104), in accordance with an exemplary embodiment of the present disclosure;
Figure 3 illustrates a modified godet roller (104), in accordance with the present disclosure;
Figure 4(A) illustrates an arrangement of four godet rollers (102) and modified godet roller (104) in a spinning apparatus, in accordance with an embodiment the present disclosure;
Figure 4(B) illustrates a spinning apparatus of Figure 4(A) wherein a godet roller (102) is replaced by modified godet roller (104), in accordance with another embodiment of the present disclosure;
Figure 5(A) illustrates an arrangement of five godet rollers (102) and modified godet roller (104) in a spinning apparatus, in accordance with an embodiment the present disclosure;
Figure 5(B) illustrates a spinning apparatus of Figure 5(A) wherein a godet roller (102) is replaced by modified godet roller (104), in accordance with another embodiment of the present disclosure;
Figure 6(A) illustrates an arrangement of six godet rollers (102) and modified godet roller (104) in a spinning apparatus, in accordance with an embodiment the present disclosure; and
Figure 6(B) illustrates a spinning apparatus of Figure 6(A) wherein a godet roller (102) is replaced by modified godet roller (104), in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Conventionally, incorporation of texture and/or dye shade variation in a fabric requires expensive and tedious methods as well as complicated apparatus. This is usually achieved by knitting and weaving two or more different types of yarns fed by use of multiple feeder units. Other methods for achieving dye shade variation is by use of processes such as sectional dyeing. However, there is no single bath dyeing process that can lead to dye shade variation in a fabric.
Further, it is not only important to reduce the cost and complications of the texturization process, but also to be able to control the level of texturization, as this aspect also affects the property of the fabric.
Therefore, the present disclosure provides an apparatus and a process for preparation of the texturized yarn.
In first aspect and in accordance with Figure 1(A), the present disclosure provides an apparatus (100) for preparing texturized yarn whose bulk density varies along its length. The apparatus (100) comprises a plurality of sequential godet rollers (102).
In one embodiment and with reference to Figure 1(A), at least one of the plurality of sequential godet rollers (102) is a modified godet roller (104).
In another embodiment and with reference to Figure 1(B), a godet roller (102) is replaced by modified godet roller (104).
The modified godet roller (104) comprises plurality of contacting segments (104A) and plurality of non-contacting segments (104B) on its exterior surface, as illustrated in Figure 2.
The apparatus comprises driving means (not shown in the figure) connected to the plurality of sequential godet rollers, wherein the at least one driving means is configured to spin the plurality of sequential godet rollers around its axis.
In an embodiment, the modified godet roller (104) is spun by a motor (202), as shown in Figure 3.
The apparatus comprises a heating means coupled to the modified godet roller (104) for heating the modified godet roller (104).
In an embodiment, the modified godet roller (104) is heated using a heating coil (204) present inside the cylindrical part of the modified godet roller (104), as shown in Figure 3.
In one embodiment, the length of each non-contacting segment (104B) is same. In another embodiment, the length of each non-contacting segment (104B) is different.
The plurality of contacting segments (104A) and non-contacting segments (104B) are alternately present on the exterior surface of the modified godet roller (104).
The number of the contacting segments (104A) and/or the number of the non-contacting segments (104B) on each modified godet roller (104) are in the range of 2 to 50. In an exemplary embodiment, the number of the contacting segments (104A) is 6 and the number of the non-contacting segments (104B) is 6.
Typically, the plurality of contacting segments (104A) and the plurality of non-contacting segments (104B) define a shape selected from the group consisting of step up-down, sinusoidal and gear-shaped. In an exemplary embodiment, the shape is sinusoidal.
In one embodiment and with reference to Figure 4(A), a spinning apparatus 300A comprises four godet rollers (102) and one modified godet roller (104).
In another embodiment and with reference to Figure 4(B), a spinning apparatus of Figure 4(A) is modified by replacing one godet roller (102) with a modified godet roller (104).
In one embodiment and with reference to Figure 5(A), a spinning apparatus 400A comprises five godet rollers (102) and one modified godet roller (104).
In another embodiment and with reference to Figure 5(B), a spinning apparatus of Figure 5(A) is modified by replacing one godet roller (102) by a modified godet roller (104).
In one embodiment and with reference to Figure 6(A), a spinning apparatus 500A comprises six godet rollers (102) and one modified godet roller (104).
In another embodiment and with reference to Figure 6(B), a spinning apparatus of Figure 6(A) is modified by replacing one godet roller (102) by a modified godet roller (104).
The apparatus further comprises a unit for combining the texturized filaments.
In another aspect, the present disclosure provides a modified godet roller (104) comprising a plurality of contacting segments (104A) and a plurality of non-contacting segments (104B) on the exterior surface of the roller as shown in Figure 2.
At least one contacting segment (104A) is configured to contact a filament spinning through the modified godet roller (104) and wherein at least one non-contacting segment (104B) is configured to be devoid of contact with the filament.
In yet another aspect, the present disclosure provides a process for preparing the texturized yarn whose bulk density varies along its length, by using the apparatus as illustrated in Figure 1(A).
The process comprises a step of obtaining filaments by melt-spinning of a polymer. The filaments are spun onto a plurality of sequential godet rollers (102), to obtain a plurality of texturized filaments varying in bulk density along its length, wherein at least one of the plurality of sequential godet rollers (102) is a modified godet roller (104) heated to a pre-determined temperature.
The pre-determined temperature of the modified godet roller (104) is in the range of 60 °C to 220 °C. In an exemplary embodiment, the pre-determined temperature of the modified godet roller (104) is 110 °C.
As illustrated in Figure 2, the modified godet roller (104) comprises a plurality of contacting segments (104A) and a plurality of non-contacting segments (104B) on exterior surface of the modified godet roller (104), wherein the at least one filament spinning through the modified godet roller (104) is in contact with at least one contacting segment (104A) and is devoid of contact with the plurality of non-contacting segments (104B).
The plurality of texturized filaments are further combined to obtain a texturized yarn.
Conventionally, the partially oriented yarn (POY) or Fully drawn yarn (FDY) upon heating tend to develop a heat memorable effect. The heat memorable effect tends to affect the molecular chain orientation of the heated portion, thereby leading to change in total crystallinity of the heated portion. The present disclosure uses a simple, economical and practically effective approach by employing the concept of heat application to lengthwise segments in filaments in a conventional spinning apparatus, which leads to the formation of repeated segments varying in total percentage crystallinity and bulk density along the length.
The modified godet roller (104) spins at a speed in the range of 500 mpm to 4500 mpm. In an embodiment, the modified godet roller (104) spins at a speed of 1482 mpm.
The filaments are selected from the group consisting of a partially oriented yarn (POY) and fully drawn yarn (FDY).
In one embodiment, the partially oriented yarn (POY) is used. The spun filaments of the POY yarn, upon introduction in the modified godet roller, come in contact with at least one contacting segment (104A) of the modified godet roller (104). As the modified godet roller (104) is heated, the part of the filaments touching the contacting segment (104A) get changed in the molecular orientation, which is generated during the spinning. The interaction of the spun filaments with plurality of contacting segments (104A) leads to repeated parts having variation in molecular orientation and hence lengthwise variation in crystallinity and bulk density along the length of the yarn. As the POY filaments are processed in machine for forming draw textured yarn (DTY), the DTY filaments tend to have several short, repeated length segments having amorphous and crystalline nature.
In another embodiment, the fully drawn yarn (FDY) is used. The interaction of fully drawn yarn (FDY) with a modified godet roller is done at any stage such as post-spinning, post-finish application, prior to drawing or post spinning but before finish application and drawing. The heated modified godet roller (104) leads to change in molecular orientation, which is generated during the spinning. The heated segments of the filaments tend to draw differently than the segments which are not in contact with the contacting segments and hence not heated, which leads to slub (thick-thin) effect through the segment in filament along its length.
In one embodiment, the filaments are dye-doped.
In accordance with the present disclosure, the process further comprises a step of dyeing the texturized yarn to obtain a dyed yarn varying in dye shade along its length, wherein the texturized yarn has different uptake of dye along its length. The variation of amorphous and crystalline part in the length segments of the yarn, caused by the interaction of the yarn with the modified godet roller, leads to variation in dye pickup, thus causing variation in the dye shade along the length.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Example 1:
A POY yarn with 126/72 denier was textured using spinning apparatus having a modified godet roller. The modified godet roller was spun at a speed of 1482 metres per minutes. The temperature of the godet roller was set at 110 °C. The parameters of the process are illustrated in Tables 1-3 below. The process of the present disclosure provided a texturized yarn having variation of bulk density along its length.
Table 1 provides the process parameters of godet roller
Parameter Value
POY denier 126/72
Spinning Roll speed
(in rpm) 5302
Spinning Roll Surface speed (in mpm) 2540
Spinning Roll frequency
(in Hz) 88.38
No of pole of motor 2
Spinning Roll diameter (m) 0.2032
Spinning Roll radius (m) 0.1016
Table 2 provides the godet roller parameters and length of POY yarn and the DTY yarn
Circumference of roller POY length (in metres) DTY length (in metres)
2*3.14*r 0.63805 1.08468
8 section 0.07976 0.13559
12 section 0.05317 0.09039
16 section 0.03988 0.06779
Table 3 provides the details of the contact time and contact length of the yarn with the modified godet roller
Angle
(Degree) ? ? (rad.) Contact length (in metres) Contact time (in minutes)
At m/c Speed-2540 mpm Contact time (in seconds)
60 p/3 1.0467 0.1063 0.000042 0.002512
90 p/2 1.5700 0.1595 0.000063 0.003768
120 2p/3 2.0933 0.2127 0.000084 0.005024
180 p 3.1400 0.3190 0.000126 0.007536
Example 2:
A POY yarn with 150/72 denier was textured using spinning apparatus having 4 godet rollers and one modified godet roller. The 4 godet rollers G1, G2, G3, G4 were spun at a speed of 1482, 1481, 3258 and 3258 respectively. The modified godet roller was spun at a speed of 1482 metres per minutes. The temperature of the godet roller was set at 110°C. The parameters are illustrated in Tables 4-6 below. The process of the present disclosure provided a textured yarn whose bulk density varies along its length.
Table 4 provides the parameters for obtaining texturized yarn having variation in the bulk density along its length
Parameter Value
POY denier 150/72
Modified Godet Speed (in mpm) 1482
Godet -1 speed (in mpm) 1482
Godet -2 speed (in mpm) 1481
Godet -3 speed (in mpm) 3258
Godet -4 speed (in mpm) 3258
Winding speed (in mpm) 3250
Spinning roll diameter (in metres) 0.2032
Spinning roll radius (in metres) 0.1016
Table 5 provides the length of the POY yarn and the FDY yarn
Circumference of roller POY length (in metres) FDY length (in metres)
2*3.14*r 0.63805 1.40371
8 section 0.07976 0.17546
12 section 0.05317 0.11698
16 section 0.03988 0.08773
Table 6 provides the details of the contact time and contact length of the yarn with the modified godet roller
Angle
(Degree) ? ? (rad.) Contact length (in metres) Contact time (in minutes)
Contact time (in seconds)
60 p/3 1.0467 0.1063 0.000072 0.004305
90 p/2 1.5700 0.1595 0.000108 0.006458
120 2p/3 2.0933 0.2127 0.000144 0.008611
180 p 3.1400 0.3190 0.000215 0.012916
The process of the present disclosure provides a texturized yarn varying in bulk density along the length. The texturized yarn obtained by the process of the present disclosure are capable of providing variation in shades along the length using single bath dye.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages, including but not limited to, the realization of:
• a process and an apparatus that:
? gives texturized yarn, wherein the bulk density of each filament varies along its length;
? is simple and economical than the conventional process; and
• an apparatus, which
? enables controlling the level of texturization variation in denier; and
? imparts improved aesthetic characteristics to the textile.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

,CLAIMS:WE CLAIM:
1. An apparatus (100) for preparing texturized yarn, said apparatus comprising:
• a plurality of sequential godet rollers (102), wherein at least one of said plurality of sequential godet rollers (102) is a modified godet roller (104), wherein the modified godet roller (104) comprises a plurality of contacting segments (104A) and a plurality of non-contacting segments (104B) on the exterior surface of the modified godet roller (104);
• at least one driving means connected to the plurality of sequential godet rollers (102), wherein said at least one driving means is configured to spin each of said plurality of sequential godet rollers (102) around its axis; and
• a heating means coupled to said modified godet roller (104) for heating said modified godet roller (104).
2. The apparatus (100) as claimed in claim 1 further comprises a unit for combining said plurality of texturized filaments.
3. The apparatus (100) as claimed in claim 1, wherein said plurality of contacting segments (104A) and said plurality of non-contacting segments (104B) are alternatively present on the exterior surface of the modified godet roller (104).
4. The apparatus (100) as claimed in claim 1, wherein the number of said contacting segments (104A) and/or the number of said non-contacting segments (104B) on each said modified godet roller (104) are in the range of 2 to 50.
5. The apparatus (100) as claimed in claim 1, wherein said plurality of contacting segments (104A) and said plurality of non-contacting segments (104B) define a shape selected from the group consisting of step up-down, sinusoidal and gear-shaped.
6. A modified godet roller (104) comprising a plurality of contacting segments (104A) and a plurality of non-contacting segments (104B) on the exterior surface of said modified godet roller (104), wherein at least one contacting segment (104A) is configured to contact a filament spinning through said modified godet roller (104) and wherein said plurality of non-contacting segments (104B) are devoid of contact with the filament.
7. A process for preparing a texturized yarn, said process comprising the following steps:
(i) obtaining filaments by melt-spinning of a polymer;
(ii) spinning said filaments onto a plurality of sequential godet rollers (102), to obtain a plurality of texturized filaments varying in bulk density along its length, wherein at least one of said plurality of sequential godet rollers (102) is a modified godet roller (104) heated to a pre-determined temperature, wherein said modified godet roller (104) comprises a plurality of contacting segments (104A) and a plurality of non-contacting segments (104B) on the exterior surface of the modified godet roller (104), wherein said filaments spinning through said modified godet roller (104) are in contact with at least one contacting segment (104A) and are devoid of contact with the plurality of non-contacting segments (104B); and
(iii) combining said plurality of texturized filaments to obtain the texturized yarn.

8. The process as claimed in claim 7, wherein said filaments are dye-doped.
9. The process as claimed in claim 7 further comprises a step of dyeing said texturized yarn to obtain a dyed yarn varying in dye shade along its length, wherein the texturized yarn has differential uptake of dye along its length.
10. The process as claimed in claim 7, wherein said pre-determined temperature of the modified godet roller is in the range of 60 °C to 220 °C.
11. The process as claimed in claim 7, wherein said modified godet roller (104) spins at a speed in the range of 500 to 4500 mpm.
12. The process as claimed in claim 7, wherein said filaments are at least one selected from the group consisting of partially oriented yarn (POY) and fully drawn yarn (FDY).