Color yarn manufacturing method, color yarn, fabric, and spinning machine

Abstract

To provide a method to enable a color to be easily changed when manufacturing a yarn and manufacture a color yarn including a core fiber, and also to provide a color yarn, a fabric, and a spinning machine.SOLUTION: A yarn Y having at least two colors is manufactured by winding a cover fiber 210 having a color different from that of a core fiber 200 around the core fiber 200 including at least one of a monofilament, a multifilament, and an elastic fiber.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a method for manufacturing colored yarns, colored yarns, fabrics, and spinning machines.

Background Art

[0002] Conventionally, for example, the production of yarns in an air spinning device has been mentioned (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When manufacturing colored yarns, a sliver in which two types of fibers are pre-mixed has been used to manufacture colored yarns by the air spinning device described in Patent Document 1. In this case, for example, in order to change the color, it is necessary to change the sliver supplied to the air spinning device, which requires time and effort for the work. Also, the production of colored yarns containing core fibers has been desired.

[0005] An object of the present invention is to provide a method for manufacturing colored yarns, colored yarns, fabrics, and spinning machines that can easily change the color during yarn production and can manufacture colored yarns containing core fibers.

Means for Solving the Problems

[0006] [1] In a method for manufacturing a colored yarn according to one aspect of the present invention, at least two-color colored yarns are manufactured by winding cover fibers of a color different from the core fiber around a core fiber including at least one of a monofilament, a multifilament, and an elastic fiber.

[0007] According to the method of [1] above, a colored yarn containing core fibers can be manufactured. For example, just by changing only the core fibers, the color of the colored yarn can be changed. Note that the cover fibers may also be changed. Therefore, the color can be easily changed during the production of the colored yarn. It is possible to produce a variety of mélange yarns.

[0008] [2] In the method of [1] above, the core fibers may be colored by original dyeing at the stage where the core fibers are manufactured. For example, when the core fibers are manufactured through a dyeing process, the manufacturing period will become long. Also, the dyeing process is not preferable from the perspective of environmental load. Coloring by original dyeing leads to a shortening of the manufacturing period (delivery time) and is also preferable from the perspective of environmental load.

[0009] [3] In the method of [1] or [2] above, a first winding unit and a second winding unit are provided in one spinning machine, and the colors of the core fibers in the first winding unit and the second winding unit may be different. In this case, different-colored colored yarns can be manufactured among the plurality of winding units provided in one spinning machine. That is, the color of the colored yarn manufactured in the first winding unit can be made different from the color of the colored yarn manufactured in the second winding unit. Also, making the colors of the core fibers different means that the core yarn packages set in the core yarn supply device are different. In this specification, when simply referring to "color", it may mean a color as a single color such as black, white, red, orange, blue, yellow, green, brown, gray, etc., and may also mean a "color tone" including concepts such as concentration and appearance.

[0010] [4] In the method of [3] above, the colors of the cover fibers in the first winding unit and the second winding unit may be the same. In this case, different-colored colored yarns can be easily manufactured among the plurality of winding units provided in one spinning machine. It is only necessary to arrange the same type of sliver, and the working efficiency is also improved. Also, for example, there will be no problem even if the fly cotton generated by the cover fibers in the first winding unit adheres to the second winding unit.

[0011] [5] In any one of the methods [1] to [4] above, the color tone of the colored yarn may be changed by changing the weight ratio of the cover fiber to the core fiber. The change in the weight ratio is easy. Therefore, the color tone of the produced colored yarn can be easily changed.

[0012] [6] In any one of the methods [1] to [5] above, the color tone of the colored yarn may be changed by changing at least one of the number, shape, and thickness of the core fibers. The change in these specifications regarding the core fibers is easy. Therefore, the color tone of the produced colored yarn can be easily changed.

[0013] [7] In any one of the methods [1] to [6] above, the color tone of the colored yarn may be changed by changing the spinning speed. The change in the spinning speed is easy. Therefore, the color tone of the produced colored yarn can be easily changed.

[0014] [8] In any one of the methods [1] to [7] above, the color tone of the colored yarn may be changed by changing at least one of the speed ratio and the tension value. The change in these operating conditions is easy. Therefore, the color tone of the produced colored yarn can be easily changed.

[0015] [9] A colored yarn produced by any one of the methods [1] to [8] above may be provided.

[0016]

[10] A fabric containing the colored yarn of [9] above may be provided.

[0017]

[11] A spinning machine according to another aspect of the present invention includes a core yarn supply device that supplies a core yarn made of a core fiber including at least one of a monofilament, a multifilament, and an elastic fiber, a drafting device that drafts a fiber bundle having a color different from that of the core fiber, and an air jet spinning device that spins the fiber bundle drafted by the drafting device with the core yarn supplied from the core yarn supply device as a core, thereby generating a colored yarn having at least two colors in which the fiber bundle is wound around the core yarn as a cover fiber, and a winding device that winds the colored yarn onto a package.

[0018] According to the spinning machine of

[11] above, the color of the colored yarn can be changed only by changing the core fiber set in the core yarn supply device. In addition, in order to change the color of the colored yarn, the cover fiber may be changed. Therefore, the color can be easily changed during the production of the colored yarn. It is possible to produce a wide variety of mélange-colored yarns.

[0019]

[12] The colored yarn according to another aspect of the present invention includes a core fiber containing at least one of a monofilament, a multifilament, and an elastic fiber, and a cover fiber having a color different from that of the core fiber and wound around the core fiber. The colored yarn is a yarn presenting a mélange tone having at least two colors.

[0020] According to the colored yarn of

[12] above, the color of the colored yarn can be changed only by changing the core fiber. In addition, in order to change the color of the colored yarn, the cover fiber may be changed. Therefore, the color can be easily changed during the production of the colored yarn. It is possible to produce a wide variety of mélange-colored yarns.

Advantages of the Invention

[0021] According to the present invention, a colored yarn containing a core fiber can be manufactured. The color can be easily changed during the production of the colored yarn.

Brief Description of the Drawings

[0022]

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Mode for Carrying Out the Invention

[0023] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the description of the drawings, the same reference numerals are given to the same elements, and duplicate descriptions are omitted.

[0024] As shown in Fig. 1, a spinning machine 1 (air spinning machine) includes a plurality of spinning units (winding units) 2, a yarn splicing carriage 3, a first end frame 4, and a second end frame 5. The plurality of spinning units 2 are arranged in a row. Each spinning unit 2 generates a yarn (colored yarn) Y and winds the yarn Y onto a bobbin B to form a package P. When the yarn Y is cut in a certain spinning unit 2 or the yarn Y breaks for some reason, the yarn splicing carriage 3 performs a yarn splicing operation on the spinning unit 2. The first end frame 4 houses an air supply source for generating a swirling flow of air or the like in each part of the spinning unit 2 and / or a suction source for generating a suction flow in each part of the spinning unit 2.

[0025] The second end frame 5 houses a drive motor or the like for supplying power to each part of the spinning unit 2. The second end frame 5 is provided with a machine control device E, a display unit D, and an input key G. The machine control device E centrally manages and controls each part of the spinning machine 1. The display unit D can display information regarding the setting contents and / or states of the spinning units 2. By appropriately operating the input key G by an operator, the setting operation of the spinning units 2 can be performed.

[0026] In the following description, in the running paths of the sliver S, fiber bundle F, and yarn Y, the side where the sliver S is supplied is referred to as the upstream side, and the side where the yarn Y is wound up is referred to as the downstream side. The side where the yarn Y runs with respect to the spinning unit 2 is referred to as the front side, and the opposite side is referred to as the rear side. In the present embodiment, a work passage (not shown) extending in the arrangement direction of the plurality of spinning units 2 is provided on the front side of the spinning machine 1. The operator can perform operations and monitoring of each spinning unit 2 from the work passage.

[0027] As shown in FIGS. 1 and 2, each spinning unit 2 includes, in order from the upstream side, a drafting device 6 and a core yarn supply device 7, an air spinning device 8, a yarn monitoring device 9, a tension detection sensor 10, a yarn storage device 11, a waxing device 12, and a winding device 13. These devices are directly or indirectly supported by the machine frame such that the upstream side is on the upper side in the machine frame height direction (i.e., the downstream side is on the lower side in the machine frame height direction).

[0028] The unit controller 15 is provided for every predetermined number of spinning units 2 and controls the operation of the spinning unit 2. The unit controller 15 controls the operation of the spinning unit 2 based on information (signals) output from the machine frame control device E.

[0029] The drafting device 6 drafts the sliver S. The drafting device 6 includes, in order from the upstream side in the running direction of the sliver S, a back roller pair 16, a third roller pair 17, a middle roller pair 18, and a front roller pair 19. Each roller pair 16, 17, 18, 19 includes a bottom roller and a top roller. The bottom roller is rotationally driven by a drive motor provided on the second end frame 5 or a drive motor provided on each spinning unit 2. An apron belt 18a is provided for the top roller of the middle roller pair 18. An apron belt 18b is provided for the bottom roller of the middle roller pair 18.

[0030] The core yarn supply device 7 unwinds the core yarn C from the core yarn package CP and supplies the core yarn C to the drafting device 6. Specifically, the core yarn supply device 7 supplies the core yarn C onto the running path of the fiber bundle F between the middle roller pair 18 and the front roller pair 19. Thereby, the core yarn C supplied from the core yarn supply device 7 is supplied to the air spinning device 8.

[0031] The air spinning device 8 takes the core yarn C supplied from the core yarn supply device 7 as the core and gives twist to the fiber bundle F drafted by the drafting device 6 by means of a swirling air flow to generate a yarn Y. More specifically (although not shown in the figure), the air spinning device 8 has a spinning chamber, a fiber guiding part, a swirling air flow generating nozzle, and a hollow guide shaft body. The fiber guiding part guides the core yarn C supplied from the core yarn supply device 7 arranged upstream and the fiber bundle F supplied from the drafting device 6 into the spinning chamber. The swirling air flow generating nozzle is arranged around the path along which the core yarn C and the fiber bundle F travel. When air is jetted from the swirling air flow generating nozzle, a swirling air flow is generated in the spinning chamber. By this swirling air flow, the respective fiber ends of the plurality of fibers constituting the fiber bundle F are inverted and swirled. The hollow guide shaft body guides the yarn Y from inside the spinning chamber to the outside of the air spinning device 8.

[0032] The yarn monitoring device 9 monitors information on the running yarn Y between the air spinning device 8 and the yarn storage device 11 and detects the presence or absence of a yarn defect based on the monitored information. When the yarn monitoring device 9 detects a yarn defect, it transmits a yarn defect detection signal to the unit controller 15. The yarn monitoring device 9 detects, as a yarn defect, for example, an abnormality in the thickness of the yarn Y and / or a foreign object contained in the yarn Y. The yarn monitoring device 9 also detects a yarn breakage and the like. The tension detection sensor 10 measures the tension of the running yarn Y between the air spinning device 8 and the yarn storage device 11 and transmits a tension measurement signal to the unit controller 15. When the unit controller 15 determines that there is an abnormality based on the detection result of the yarn monitoring device 9 and / or the tension detection sensor 10, the yarn Y is cut in the spinning unit 2.

[0033] Specifically, the supply of air to the air spinning device 8 is stopped, and the production of the yarn Y is interrupted, whereby the yarn Y is cut. Alternatively, the yarn Y may be cut by a separately provided cutter. In relation to the interruption of spinning by the air spinning device 8, the drafting operation by the drafting device 6 (specifically, the rotation of the back roller pair 16 and the third roller pair 17) and the supply operation of the core yarn C by the core yarn supply device 7 are stopped.

[0034] The waxing device 12 applies wax to the yarn Y between the yarn storage device 11 and the winding device 13.

[0035] The yarn storage device 11 stores the yarn Y between the air spinning device 8 and the winding device 13. The yarn storage device 11 includes a yarn storage roller on which the yarn Y is wound around the outer peripheral surface to store the yarn Y. The yarn storage device 11 has a function of stably drawing the yarn Y from the air spinning device 8, a function of preventing the yarn Y from loosening by retaining the yarn Y sent out from the air spinning device 8 during the yarn splicing operation by the yarn splicing truck 3, etc., and a function of preventing the variation in the tension of the yarn Y on the downstream side from being transmitted to the air spinning device 8.

[0036] The take-up device 13 winds the yarn Y produced by the air spinning device 8 onto the bobbin B to form the package P. The take-up device 13 has a cradle arm 21, a take-up drum 22, and a traverse guide 23. The cradle arm 21 rotatably supports the bobbin B. The cradle arm 21 is swingably supported by a support shaft 24, and the surface of the bobbin B or the surface of the package P is brought into contact with the surface of the take-up drum 22 with an appropriate pressure. A drive motor (not shown) provided on the second end frame 5 drives the take-up drums 22 of the plurality of spinning units 2 all at once. Thereby, in each spinning unit 2, the bobbin B or the package P is rotated in the winding direction. The traverse guide 23 of each spinning unit 2 is provided on a shaft 25 shared by the plurality of spinning units 2. The drive motor of the second end frame 5 reciprocally drives the shaft 25 in the rotation axis direction of the take-up drum 22, so that the traverse guide 23 traverses the yarn Y with a predetermined width with respect to the rotating bobbin B or package P.

[0037] When the yarn splicing carriage 3 travels to a certain spinning unit 2 when the yarn Y is cut or breaks for some reason in the spinning unit 2, and performs a yarn splicing operation. The yarn splicing carriage 3 has a yarn splicing device 26, a suction pipe 27, and a suction nozzle 28. The suction pipe 27 is rotatably supported by a support shaft 27a, captures the yarn Y from the air spinning device 8, and guides it to the yarn splicing device 26. The suction nozzle 28 is rotatably supported by a support shaft 28a, captures the yarn Y from the take-up device 13, and guides it to the yarn splicing device 26. The yarn splicing device 26 splices the guided yarns Y together. The yarn splicing device 26 is a splicer using air or a knitter that mechanically joins the yarn Y, etc.

[0038] When the yarn splicing carriage 3 performs a yarn splicing operation, the package P is rotated (reverse rotation) in the reverse winding direction. At this time, the cradle arm 21 is moved by an air cylinder (not shown) so that the package P is separated from the take-up drum 22, and the package P is reversely rotated by a reverse rotation roller (not shown) provided on the yarn splicing carriage 3.

[0039] Next, the core yarn supply device 7 will be described in detail. As shown in FIG. 2, the core yarn supply device 7 includes a package support portion 50, a core yarn supply unit 51, and a core yarn guide portion 52.

[0040] The package support portion 50 holds the core yarn package CP in a state where the center line of the core yarn package CP extends horizontally and in the front-rear direction. The core yarn package CP is formed by winding the core yarn C around a core yarn bobbin (not shown). The core yarn C is unwound from the core yarn package CP and supplied to the core yarn supply unit 51 via a guide roller 53 that guides the core yarn C.

[0041] The core yarn supply unit 51 has a function of applying tension to the supplied core yarn C, a function of imparting slack to the core yarn C, and a function of feeding out the core yarn C (the yarn end of the core yarn C). The core yarn guide portion 52 is a cylindrical member that guides the core yarn C to the drafting device 6.

[0042] As shown in FIG. 3, the core yarn supply unit 51 includes a unit base 60, a tension applying mechanism 70, a slack applying mechanism 80, a core yarn monitoring device 90, and a core yarn feeding mechanism 100. In the following description, in the running path of the core yarn C in the core yarn supply unit 51, the core yarn package CP side is referred to as the upstream side, and the core yarn guide portion 52 side is referred to as the downstream side.

[0043] The unit base 60 supports the tension applying mechanism 70, the slack applying mechanism 80, the core yarn monitoring device 90, and the core yarn feeding mechanism 100 in order from the upstream side in the supply direction of the core yarn C. A core yarn guide 61 for guiding the core yarn C is provided on the most upstream side of the unit base 60.

[0044] The tension applying mechanism 70 applies tension to the core yarn C on the downstream side in the supply direction of the core yarn C from the core yarn guide 61. As shown in FIG. 4, the tension applying mechanism 70 has a tension applying portion 71 and a holding portion 72.

[0045] As shown in FIG. 4(a), the tension applying portion 71 has a fixed piece (bending portion) 73 and a movable piece (bending portion) 74. The tension applying portion 71 bends the core yarn C multiple times by alternately winding the core yarn C around the fixed piece 73 and the movable piece 74. The number of times the core yarn C is bent is, for example, 20 times or less (preferably 2 to 10 times).

[0046] The fixed piece 73 is fixed to the unit base 60. The movable piece 74 is supported by a support shaft (not shown) provided on the fixed piece 73 and is openable / closable (rotatable) with respect to the fixed piece 73. The movable piece 74 is biased in the opening direction with respect to the fixed piece 73 by a spring (not shown) provided on the fixed piece 73.

[0047] As a more specific configuration, a plurality of shafts 73a are provided on the fixed piece 73 at a predetermined interval in the supply direction of the core yarn C. A plurality of protrusions 74a protruding toward the fixed piece 73 side are provided on the movable piece 74. When the movable piece 74 closes with respect to the fixed piece 73 (the state shown in FIG. 4(b)), each of these protrusions 74a is alternately positioned with each shaft 73a in the supply direction of the core yarn C. A hole 74b through which the core yarn C is passed is formed at the tip portion of each protrusion 74a. The core yarn C is alternately wound around each shaft 73a and each hole 74b.

[0048] As shown in FIG. 4(a), when the movable piece 74 opens with respect to the fixed piece 73, the core yarn C is bent multiple times. Thereby, tension is applied to the core yarn C. The state of the tension applying portion 71 at this time is referred to as a tension applying state. As shown in FIG. 4(b), when the movable piece 74 closes with respect to the fixed piece 73, the core yarn C becomes substantially straight. Thereby, tension is no longer applied to the core yarn C. The state of the tension applying portion 71 at this time is referred to as a non-tension applying state.

[0049] The holding portion 72 opens and closes the movable piece 74 with respect to the fixed piece 73. As shown in FIGS. 4(a) and 4(b), the holding portion 72 has a holding member 75 and an air cylinder 76.

[0050] The holding member 75 is brought into contact with and separated from the movable piece 74 by the air cylinder 76. More specifically, the holding member 75 is provided with a tip portion 75a that contacts the movable piece 74 from the opposite side of the fixed piece 73. When air is supplied to the air cylinder 76, the tip portion 75a is moved downward (in the direction in which the movable piece 74 closes with respect to the fixed piece 73). When the supply of air to the air cylinder 76 is stopped, the tip portion 75a is separated from the movable piece 74 and moved upward (in the direction in which the movable piece 74 opens with respect to the fixed piece 73).

[0051] When the tip portion 75a moves downward, the movable piece 74 is pressed by the tip portion 75a and closes with respect to the fixed piece 73. Therefore, the tension applying portion 71 is in a non-tension applying state. When the tip portion 75a moves upward, the movable piece 74 opens with respect to the fixed piece 73 by the biasing force of the spring. Therefore, the tension applying portion 71 is in a tension applying state.

[0052] The slack applying mechanism 80 applies slack to the core thread C on the downstream side in the supply direction of the core thread C from the tension applying mechanism 70. As shown in FIG. 3, the slack applying mechanism 80 includes a slack applying portion 81 and an air cylinder 82. The slack applying portion 81 is an arm rotatably supported by a support shaft 81c attached to the unit base 60. The slack applying portion 81 is rotated by the air cylinder 82.

[0053] As a more specific configuration, a hole portion 83 through which the core thread C passes is provided at the tip portion of the slack applying portion 81. When air is supplied to the air cylinder 82, the hole portion 83 is moved to a position away from the traveling path of the core thread C (the position of the two-dot chain line in FIG. 3). When the supply of air to the air cylinder 82 is stopped, the hole portion 83 is moved to the traveling path of the core thread C (the position of the solid line in FIG. 3).

[0054] When the hole portion 83 is moved from the traveling path of the core yarn C (the position of the solid line in FIG. 3) to a position away from the traveling path of the core yarn C (the position of the dashed two-dot line in FIG. 3), the core yarn C is pulled upward while catching on the edge of the hole portion 83. Since the core yarn C is unwound from the core yarn package CP by the amount it is pulled upward, slack is imparted to the core yarn C. In this way, the state of the slack imparting portion 81 when the hole portion 83 is located away from the traveling path of the core yarn C (the state of the dashed two-dot line in FIG. 3) is defined as the slack imparting state. The state of the slack imparting portion 81 when the hole portion 83 is located in the traveling path of the core yarn C (the state of the solid line in FIG. 3) is defined as the non-slack imparting state.

[0055] The core yarn monitoring device 90 detects the presence or absence of the core yarn C on the downstream side of the slack imparting mechanism 80 in the supply direction of the core yarn C. Core yarn guides 62 and 63 for guiding the core yarn C are arranged on the upstream side and the downstream side of the core yarn monitoring device 90, respectively. The location where the core yarn monitoring device 90 is provided is not limited to the above location, and it may be provided upstream of the tension imparting portion 71 as long as it is downstream of the core yarn guide 61.

[0056] The core yarn sending mechanism 100 has a function of sending the core yarn C to the drafting device 6, a function of clamping the core yarn C, and a function of cutting the core yarn C. The downstream end (exit) of the core yarn sending mechanism 100 is provided so as to face the position between the middle roller pair 18 and the front roller pair 19 of the drafting device 6 via the core yarn guiding portion 52. The core yarn sending mechanism 100 has a clamp portion, a cutter, and an air cylinder (all not shown).

[0057] The core yarn sending mechanism 100 sends the core yarn C to the drafting device 6 downstream of the tension imparting mechanism 70 and the slack imparting mechanism 80 in the core yarn traveling direction. The clamp portion clamps the core yarn C (the yarn end of the core yarn C) inside the core yarn sending mechanism 100. The cutter has a function of cutting the core yarn C clamped by the clamp portion. When air is supplied to the air cylinder, the clamp portion clamps the core yarn C.

[0058] The cutter cuts the core thread C downstream of the clamping portion in the core thread running direction. The cutter is operated in conjunction with the clamping portion by an air cylinder. The cutter cuts the core thread C when the clamping portion is switched from the unclamped state to the clamped state.

[0059] As the core thread supply device 7, for example, the configuration described in Japanese Patent Laid-Open No. 2016-79540 is adopted, but instead, other known configurations can be adopted.

[0060] The operation of the core thread supply device 7 will be described. When the core thread C is being supplied, the tension applying portion 71 is maintained in the tension applying state, the slack applying portion 81 is maintained in the non-slack applying state, and the clamping portion of the core thread feeding mechanism 100 is maintained in the unclamped state. Thereby, the core thread supply device 7 supplies the core thread C to the drafting device 6 while applying tension.

[0061] When a thread defect is detected by the thread monitoring device 9, the tension detection sensor 10, and / or the core thread monitoring device 90, the unit controller 15 first switches the clamping portion to the clamped state to stop the supply of the core thread C. At this time, the cutter portion operates in conjunction with the clamping portion, and the core thread C on the downstream side of the clamping portion is cut. Next, the unit controller 15 switches the tension applying portion 71 to the non-tension applying state, and then switches the slack applying portion 81 to the slack applying state.

[0062] When restarting the supply of the core thread C, the unit controller 15 switches the clamping portion to the unclamped state, then switches the tension applying portion 71 to the tension applying state, and then switches the slack applying portion 81 to the non-slack applying state. Thereafter, the core thread C is sent to the drafting device 6 by the core thread feeding mechanism 100. Thereby, the supply of the core thread C is restarted.

[0063] In the spinning machine 1 of this embodiment, in each spinning unit 2, a yarn Y, which is a colored yarn having at least two colors, is produced. The core yarn C held by the core yarn supply device 7 is composed of core fibers that are long fibers. The core yarn C is, for example, a multifilament. In this case, the core yarn C is formed by bundling a plurality of filament single yarns. The core yarn C may be a monofilament. The core yarn C may be an elastic fiber. Elastic fibers are yarns having elasticity, and examples include polyurethane. Also, the sliver S supplied to the drafting device 6 is composed of short fibers. The raw material of the sliver S includes, for example, at least one of cotton, polyester, viscose, acrylic, wool, lyocell, nylon, hemp, and silk. The raw material of the sliver S includes at least one of natural fibers and chemical fibers.

[0064] FIG. 5 is a schematic diagram of the yarn Y of this embodiment. The yarn Y includes core fibers 200 disposed at a substantially central portion in the radial direction of the yarn Y, and covering fibers 210 having a color different from that of the core fibers 200 and wound around the core fibers 200. The core fibers 200 are derived from (correspond to) the core yarn C, and the covering fibers 210 are derived from (correspond to) the sliver S. "Different colors" means, for example, when the core fibers 200 are red and the covering fibers 210 are white, when the core fibers 200 are blue and the covering fibers 210 are white, when the core fibers 200 are red and the covering fibers 210 are black, when the core fibers 200 are blue and the covering fibers 210 are black, and so on. However, these are merely examples, and the combination of different colors is not particularly limited. Also, the raw material of the yarn Y may be a combination of a sliver presenting a melange tone and the core fibers 200. A sliver presenting a melange tone can be prepared by mixing fibers of different colors at the manufacturing stage of the sliver. "Different yarns" means, for example, a case of a sliver presenting a melange tone composed of white and black and red core fibers 200. The covering fibers 210 include, for example, parallel fibers 211 that extend relatively straight around the core fibers 200 and winding fibers 212 that extend helically around the core fibers 200. Since the color of the core fibers 200 is different from the color of the covering fibers 210, the yarn Y is a yarn presenting a melange tone having at least two colors (a melange yarn).

[0065] When the cover fiber 210 is white, in the yarn Y (and the fabric such as the knitted fabric KF described later), the color of the core fiber 200 can be dominant. For example, when the cover fiber 210 is white and the core fiber 200 is red, the yarn Y (and the fabric made of the yarn Y) exhibits a red-based mélange tone. When the cover fiber 210 is white and the core fiber 200 is blue, the yarn Y (and the fabric made of the yarn Y) exhibits a blue-based mélange tone. “(A certain color is) dominant” is synonymous with “(a certain color is) prominent”.

[0066] In addition, in FIG. 5, for the sake of easy viewing, the color of the parallel fiber 211 and the color of the winding fiber 212 are made slightly different. Since the parallel fiber 211 and the winding fiber 212 are fibers derived from one fiber bundle F (sliver S), the color of the parallel fiber 211 and the color of the winding fiber 212 are the same.

[0067] When the core fiber 200 constituting the core yarn C is a multifilament, the multifilament is, for example, false-twisted. The multifilament is subjected to false-twisting during the production of the multifilament. Note that the multifilament may not be false-twisted. The core yarn C may or may not be drawn.

[0068] When the core fiber 200 constituting the core yarn C is a monofilament, the monofilament is formed of a single thin filament (for example, a single filament of 30 denier or thinner).

[0069] Fig. 6 is an enlarged photograph of the yarn Y produced using a multifilament as the core fiber 200. This yarn Y consists of a 30-denier black yarn made of 36 filament single yarns and a white cover fiber 210. The weight ratio (coverage rate) of the cover fiber 210 to the core fiber 200 is 70%. In order to form a yarn Y exhibiting a mélange tone, it is preferable that the weight ratio of the cover fiber 210 to the core fiber 200 is 50% or more. As shown in Fig. 6, the core fiber 200 is exposed from the gaps (or intervals) of the cover fiber 210, and a yarn Y exhibiting a mélange tone as a whole is formed.

[0070] The core fiber 200 constituting the core yarn C is colored by original dyeing, for example, at the stage where the core fiber 200 is manufactured. Coloring by original dyeing, unlike coloring by a dyeing process, leads to a shortening of the manufacturing period (delivery time) and is also preferable from the perspective of environmental load.

[0071] The above-described spinning unit 2 (spinning machine 1) can be described as follows. Each spinning unit 2 includes a core yarn supply device 7 that supplies a core yarn C made of a core fiber 200 including at least one of a monofilament, a multifilament, and an elastic fiber, a drafting device 6 that drafts a fiber bundle F having a color different from that of the core fiber 200, and an air spinning device 8 that generates a yarn Y having at least two colors in which the fiber bundle F drafted by the drafting device 6 is wound around the core yarn C as a cover fiber 210 by spinning the core yarn C supplied from the core yarn supply device 7, and a winding device 13 that winds the yarn Y around a package P.

[0072] In a method for manufacturing a colored yarn Y, a yarn Y having at least two colors is manufactured by winding a cover fiber 210 having a color different from that of the core fiber 200 around the core fiber 200 including at least one of a monofilament, a multifilament, and an elastic fiber.

[0073] According to the method for manufacturing the yarn Y of the present embodiment, for example, the color of the yarn Y can be changed only by changing only the core fiber 200 (core yarn C). For example, in a state where the generation of the yarn Y is stopped in the spinning unit 2 (spinning machine 1), the red core yarn package CP held by the package support portion 50 is replaced with a blue core yarn package CP. Conventionally, when manufacturing a colored yarn in a certain spinning unit, there was a possibility that the colored air carded sliver would be mixed into the yarns of other spinning units (or other adjacent fiber machines). Therefore, it was necessary to take measures such as surrounding the spinning unit (or fiber machine) that manufactures the colored yarn with a cover so that the colored air carded sliver does not scatter. Further, when starting to manufacture a yarn of a color different from before in a spinning unit (or fiber machine), thorough cleaning was required so that the colored air carded sliver before the change did not remain in the spinning unit (or fiber machine). In the present embodiment, since only the core fiber 200 (core yarn C) needs to be changed, the labor for changing the color of the yarn Y is reduced. Therefore, the color can be easily changed during the manufacture of the yarn Y. It is possible to produce a variety of yarns exhibiting a mélange tone.

[0074] In addition, in order to change the color of the yarn Y, the cover fiber 210 (sliver S) may be changed. For example, in a state where the generation of the yarn Y is stopped in the spinning unit 2 (spinning machine 1), the can storing the white sliver S is replaced with a can storing the black sliver S.

[0075] As used herein, "production of a variety of products" includes forms such as simultaneously generating yarns Y of different colors in one spinning machine 1, simultaneously generating yarns Y of the same color, but generating yarns Y of different colors in a short period of time. It is also possible to separate the core fiber 200 and the cover fiber 210 by removing the cover fiber 210 wound around the outside.

[0076] Even when the cover fiber 210 is recovered as air carded sliver, it can be reused because it is not mixed with the core fiber 200. This is particularly effective when the types (colors) of the slivers S used in one spinning machine 1 are the same.

[0077] In the spinning machine 1, various manufacturing methods (specifically, changes in operating conditions, etc.) can be performed. For example, in two different spinning units 2 in one spinning machine 1, the color of the core fiber 200 (core yarn C) may be made different. In this case, yarns Y of different colors can be manufactured among the plurality of spinning units 2. That is, the color of the yarn Y manufactured in a certain spinning unit 2 can be made different from the color of the yarn Y manufactured in another spinning unit 2. Also, making the color of the core fiber 200 different means that the core yarn packages CP set in the core yarn supply device 7 are different. Even when the entire spinning machine 1 is driven by a shared shaft 25 or the like, a plurality of types of yarns Y can be easily manufactured. Note that it is not limited only to the case where the entire spinning machine 1 is driven by a shared shaft 25 or the like, and each part of the spinning unit 2 (for example, the drafting device 6, the air spinning device 8, the winding device 13, etc.) described later may be independently driven for each spinning unit 2. In this case, since each spinning unit 2 can be driven under different conditions, it can flexibly respond to multi-variety production.

[0078] In two different spinning units 2 in one spinning machine 1, the color of the cover fiber 210 may be the same. In this case, yarns Y of different colors can be easily manufactured among the plurality of spinning units 2. It is only necessary to arrange the same type of sliver (sliver S) for the plurality of spinning units 2, and the working efficiency is also improved. Also, for example, there is no problem even if the fluff generated by the cover fiber in a certain spinning unit 2 adheres to another spinning unit 2.

[0079] Also, by changing the weight ratio of the cover fiber 210 to the core fiber 200, the shade of the yarn Y can be changed. The larger the weight ratio of the cover fiber 210 to the core fiber 200, the more prominent the color of the cover fiber 210. The smaller the weight ratio of the cover fiber 210 to the core fiber 200, the more prominent the color of the core fiber 200. Changing the weight ratio is easy. Therefore, the shade of the manufactured yarn Y can be easily changed.

[0080] Also, by changing at least one of the number, shape, and thickness of the core fiber 200, the color tone of the yarn Y can be changed. The number of core fibers 200 means, for example: (1) when the core fiber 200 is a monofilament, the number of single filament yarns (i.e., 1); (2) when the core fiber 200 is a multifilament, the number of single filament yarns; (3) when the core fiber 200 is an elastic fiber, the number of single elastic fibers; (4) when the core fiber 200 is a combination of at least any two of monofilament, multifilament, and elastic fiber, it is the number included in the combination. The greater the number of core fibers 200, the more prominent the color of the core fiber 200. The shape of the core fiber 200 means, for example, at least one of the presence or absence of false twist in the core fiber 200 and the presence or absence of stretching in the core fiber 200. Alternatively, as the core fiber 200, a yarn generated to have a special shape may be used. The more complex or special the shape of the core fiber 200, the more prominent the color of the core fiber 200. The thicker the core fiber 200, the more prominent the color of the core fiber 200. The change in these specifications regarding the core fiber 200 is easy. Therefore, the color tone of the produced yarn Y can be easily changed.

[0081] Also, by changing the spinning speed, the color tone of the yarn Y can be changed. The spinning speed can be defined and controlled by the pulling speed of the yarn Y by the yarn storage device 11. In the case where the spinning machine 1 is configured to pull out the yarn Y from the air spinning device 8 by the delivery roller, the spinning speed can be defined and controlled by the pulling speed of the yarn Y by the delivery roller. The higher the spinning speed, the more prominent the color of the core fiber 200. The change in the spinning speed is easy. Therefore, the color tone of the produced yarn Y can be easily changed.

[0082] Also, by changing at least one of the speed ratio and the tension value, the color tone of the yarn Y can be changed. The speed ratio can be adjusted and controlled by the speed ratio between the front roller pair 19 and the yarn storage device 11 (or the delivery roller). Further, by adjusting the opening degree of the movable piece 74 in the tension applying mechanism 70 of the core yarn supply device 7, the tension of the core yarn C can be adjusted, and thereby the tension value can be adjusted and controlled. Adjusting the speed ratio means that the slower the peripheral speed of the yarn storage device 11 (specifically, the yarn storage roller) or the delivery roller is with respect to the peripheral speed of the bottom roller of the front roller pair 19 (that is, the smaller the speed ratio is), the more prominent the color of the core fiber 200 becomes, and the faster the peripheral speed of the yarn storage device 11 (specifically, the yarn storage roller) or the delivery roller is with respect to the peripheral speed of the bottom roller of the front roller pair 19 (that is, the larger the speed ratio is), the more prominent the color of the cover fiber 210 becomes. The smaller the tension value is, the more prominent the color of the core fiber 200 becomes, and the larger the tension value is, the more prominent the color of the cover fiber 210 becomes. Changing these operating conditions is easy. Therefore, the color tone of the produced yarn Y can be easily changed.

[0083] In addition, in the operation of the spinning machine 1, when the lot is changed (when the operating conditions are changed), for example, when the core fiber 200 (color) is changed, the setting of the yarn monitoring device 9 is reset. Particularly when using reflected light in the yarn monitoring device 9, since the amount of reflected light changes depending on the color of the core fiber 200, it is necessary to change the setting.

[0084] As another aspect of the present embodiment, a cloth containing the yarn Y manufactured by the above method may be provided. FIG. 7 is an enlarged photograph of a knitted fabric (cloth) KF obtained by knitting the yarn Y manufactured using the core fiber 200 made of monofilament. FIG. 8 is an enlarged photograph of a knitted fabric (cloth) KF obtained by knitting the yarn Y manufactured using the core fiber 200 made of multifilament. In any of the knitted fabrics KF, the black core fiber 200 and the white cover fiber 210 are used, and a melange-colored cloth is realized. In the knitted fabric KF shown in FIG. 7, the core fiber 200 in the yarn Y is 30 denier. Also in the knitted fabric KF shown in FIG. 8, the core fiber 200 in the yarn Y is 30 denier. The knitted fabric KF containing the yarn Y manufactured using the core fiber 200 made of multifilament shown in FIG. 8 is more conspicuous in black than the knitted fabric KF containing the yarn Y manufactured using the core fiber 200 made of monofilament shown in FIG. 7, and shows a clearer melange color tone. In addition, a woven fabric may be manufactured by the yarn Y manufactured by the above method (by weaving the yarn Y).

[0085] As yet another aspect of the present embodiment, in one core yarn package CP, by varying the color of the core yarn C in the length direction, a striped knitted fabric KF as shown in FIG. 9 can also be manufactured. Such a core yarn C (also called a multi-color core, etc.) can be manufactured, for example, using the method and apparatus disclosed in JP-A-2004-156186. Alternatively, by setting core yarns C having different colors in the spinning unit 2 and changing the core yarn C to be supplied every predetermined length, the color of the core yarn C can be varied in the length direction in the core yarn package CP. The predetermined length may be a constant length or may be a different length for each supply operation. Note that the present invention is not limited to the aspect of varying the color of the core yarn C in the length direction, and a core fiber 200 having a plurality of colors may be used by bundling a plurality of colored filaments (at the same position in the length direction). Further, instead of the core yarn package CP, a fiber bundle F having a plurality of colors may be used. In that case, the cover fiber 210 has a plurality of colors. Both the core yarn package CP and the fiber bundle F may have a plurality of colors.

[0086] As described above, embodiments of the present invention have been described, but the present invention is not limited to the above embodiments. The above embodiments and the following modification examples may be combined as appropriate. For example, the core fiber may be colored by a dyeing process. In all the spinning units 2 of the spinning machine 1, core yarns C having the same color may be set in each core yarn supply device 7. In at least any two spinning units 2 of the spinning machine 1, the color of the sliver S (fiber bundle F) may be different. The weight ratio of the cover fiber 210 to the core fiber 200 may be made constant (fixed). All or part of the number, shape, and thickness of the core fibers 200 may be made constant (fixed). In this case, if other conditions are the same, the color tone of the yarn Y produced in all the spinning units 2 of the spinning machine 1 is constant. The spinning speed may be made constant (fixed). In this case, if other conditions are the same, the color tone of the yarn Y produced in all the spinning units 2 of the spinning machine 1 is constant. The speed ratio and the tension value may be made constant (fixed). In this case, if other conditions are the same, the color tone of the yarn Y produced in all the spinning units 2 of the spinning machine 1 is constant.

[0087] Two different colored slivers S may be supplied. In other words, the yarn Y may contain core fibers 200 of two or more colors. The yarn Y may contain at least one of core fibers 200 of two or more colors and cover fibers 210 of two or more colors. In this case, the drafting device 6 may include a back roller pair 16, a third roller pair 17, a middle roller pair 18, and a front roller pair 19 for each sliver S.

[0088] A sensor capable of detecting the tension value of the yarn Y may be provided in the spinning machine 1 (for example, between the air spinning device 8 and the yarn storage device 11 (or delivery roller)), and the speed ratio and / or the tension applying mechanism 70 may be controlled so that the tension value becomes constant. In this case, a yarn Y having a certain melange tone can be produced.

[0089] The colored yarn is not limited to the spun yarn produced by the air spinning device 8 (air jet spinning device), and may be a spun yarn produced by a ring spinning machine.

[0090] In the above embodiment, an example of the form in which the drafting device 6 includes the back roller pair 16, the third roller pair 17, the middle roller pair 18, and the front roller pair 19 was described. However, one or more roller pairs may be provided upstream of the back roller pair 16. Further, the front roller pair (the roller pair disposed at the position closest to the air spinning device 8 in the conveyance path of the fiber bundle F) may be configured as a part of another device. For example, the spinning unit 2 includes a supply device that supplies the fiber bundle F drafted by the drafting device 6 to the air spinning device 8, and the front roller pair 19 may be included in a part of the supply device. The front roller pair 19 may be included in the drafting device 6 that drafts the fiber bundle F or the supply device that supplies the fiber bundle F to the air spinning device 8, or may be provided independently without being included in another device.

[0091] In the spinning unit 2, the yarn storage device 11 had the function of pulling out the yarn Y from the air spinning device 8, but the yarn Y may be pulled out from the air spinning device 8 by a delivery roller and a nip roller. When the yarn Y is pulled out from the air spinning device 8 by a delivery roller and a nip roller, instead of or in addition to the yarn storage device 11, a slack tube using a suction air flow and / or a mechanical compensator or the like may be provided.

[0092] In the spinning unit 2, instead of the configuration in which two yarn ends are connected by the yarn splicing device 26, the yarn Y from the package P may be inserted into the air spinning device 8, and by starting the drafting operation of the drafting device 6 and the spinning operation of the air spinning device 8, the yarn Y from the air spinning device 8 and the yarn Y of the package P may be connected (piecing).

[0093] In the spinning machine 1, in the machine base height direction, the devices were arranged such that the yarn Y supplied from above was wound up from below. However, the devices may be arranged such that the yarn supplied from below is wound up from above.

[0094] In the spinning machine 1, at least one of the bottom rollers of the drafting device 6 and the traverse guide 23 were driven by the power from the second end frame 5 (i.e., commonly for a plurality of spinning units 2). However, each part of the spinning unit 2 (for example, the drafting device 6, the air spinning device 8, the winding device 13, etc.) may be driven independently for each spinning unit 2.

[0095] In the running direction of the yarn Y, the tension detection sensor 10 may be arranged upstream of the yarn monitoring device 9. The unit controller 15 may be provided for each one spinning unit 2. In the spinning unit 2, at least any one of the waxing device 12, the tension detection sensor 10, and the yarn monitoring device 9 may be omitted. When wax is not applied to the yarn Y, only the wax may be removed from the waxing device 12 without omitting the waxing device 12.

[0096] In FIG. 1, the spinning machine 1 is illustrated as winding a cheese-shaped package P, but it is also possible to wind a cone-shaped package. In the case of a cone-shaped package, slack of the yarn Y occurs due to the traverse of the yarn Y, but the slack can be absorbed by the yarn storage device 11. The materials and shapes of each component are not limited to the materials and shapes described above, and various materials and shapes can be adopted.

Description of Reference Numerals

[0097] 1... Spinning machine, 2... Spinning unit (winding unit), 6... Drafting device, 7... Core yarn supply device, 8... Air spinning device (air jet spinning device), 13... Winding device, 15... Unit controller, Y... Yarn (colored yarn).

Claims

1. A method for manufacturing a colored yarn, comprising: wrapping a cover fiber of a color different from that of the core fiber around the core fiber containing at least one of a monofilament, a multifilament, and an elastic fiber to produce a colored yarn having at least two colors.

2. The method according to claim 1, wherein the core fiber is colored by original dyeing at the stage where the core fiber is manufactured.

3. A spinning machine is provided with a first winding unit and a second winding unit, wherein the colors of the core fibers in the first winding unit and the second winding unit are different, according to the method of claim 1 or 2.

4. The method according to claim 3, wherein the colors of the cover fibers in the first winding unit and the second winding unit are the same.

5. The method according to any one of claims 1 to 4, wherein the color tone of the colored yarn is changed by changing the weight ratio of the cover fiber to the core fiber.

6. The method according to any one of claims 1 to 5, wherein the color tone of the colored yarn is changed by changing at least one of the number, shape, and thickness of the core fibers.

7. The method according to any one of claims 1 to 6, wherein the color tone of the colored yarn is changed by changing the spinning speed.

8. The method according to any one of claims 1 to 7, wherein the color tone of the colored yarn is changed by changing at least one of the speed ratio and the tension value.

9. A colored yarn manufactured by the method according to any one of claims 1 to 8.

10. A cloth containing the colored yarn according to claim 9.

11. A core yarn supply device for supplying a core yarn composed of a core fiber containing at least one of a monofilament, a multifilament, and an elastic fiber, a drafting device for drafting a fiber bundle having a color different from that of the core fiber, an air jet spinning device for spinning the fiber bundle drafted by the drafting device with the core yarn supplied from the core yarn supply device as a core, so that the fiber bundle is wound around the core yarn as a cover fiber to generate a colored yarn having at least two colors, and a winding device for winding the colored yarn onto a package.

12. A colored yarn comprising a core fiber containing at least one of a monofilament, a multifilament, and an elastic fiber, and a cover fiber having a color different from that of the core fiber and wound around the core fiber, wherein the colored yarn exhibits a mélange tone having at least two colors.

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