[Summary] The present invention provides a compact
package of buckled
crimp yarn having high bulkiness, an inexpensive and safe manufacturing method thereof, and a manufacturing apparatus therefor. That is, it is possible to produce a releasable buckled
crimp fiber cake from a high-speed extruded
fiber using simple equipment without winding. Since buckled
crimp is imparted to said
spinning fiber at the same time as solidification, a robust and bulky crimp is imparted. Moreover, since the fiber is compressed into a cake shape in a filament-opened state, compactness of packages and bulkiness of the opened filaments are achieved all at once. Meanwhile, in a traditional buckled crimp imparting method, the
crystal structure of a fiber once fixed in a flat
yarn state tends to remain, and it is difficult to improve its bulkiness and fastness. Since a winder is not used in the present invention, the equipment is simple, and it is easy to produce many kinds of product in small quantities. Further, in the
package according to the present invention, since fibers are laminated in a columnar shape and can be divided along the lamination surface at an arbitrary portion, there is no need for rewinding for subdividing the
package. Incidentally, although flat
yarn cannot be obtained by the method of the present invention, the versatility of the resulting fiber is not impaired due to the fact that it is inherently crimped, as is the case with
wool and cotton yarn. [Problems] With conventional technology, obtaining buckled crimp yarn from a
spinning raw material required tedious processes such as
spinning, winding, unwinding, buckled crimp
processing, and rewinding. In other words, winding requires a high-speed winder and an associated automatic package switching device, and it was not easy to create an inexpensive and safe facility, or to create a facility that is flexible enough to be suitable for small-lot, high-mix production. Moreover, a fiber that has been drawn using rollers goes through a process where it is temporarily fixed as flat yarn. Therefore, even if it is later buckled crimped, the
resultant final product is likely to revert to a crystalline structure that was created on the way of the process, making it difficult to obtain a fiber with a robust buckled crimp in terms of yarn quality. Furthermore, with conventional spool-type packages, it is difficult to achieve both compactness of packages and bulkiness of released yarn. [Solution] A fiber-forming fluid is extruded from a spinneret and ejected with a pressurized gas through a narrow hole positioned opposite to the spinneret; and the
resultant fiber is made into a rod of fiber having a buckled crimp in a crimping zone provided at the end of said narrow hole; and the rod of fiber is sent and accumulated into a compressing chamber comprising a reverse funnel-like section and a hollow cylindrical section, and a releasable buckled crimp yarn cake is produced by vibrational compression from the downstream side of said compressing chamber.