Heterogeneous twin polyamide fully drawn 3d spring wire

Abstract

This invention discloses a heterocomponent twin-core polyamide fully stretched 3D spring yarn. Component 1 and Component 2 melts each have independent flow channels, and the two melts do not contact each other before exiting the spinneret orifice. For applications with low viscosity and temperature control requirements, this ensures that the two melts are extruded independently from their respective spinneret orifices. After being guided by four guide plates and having their component pressure balanced, the two melts are introduced in parallel into the receiving holes of the spinneret orifice, simultaneously injected at an oblique angle, and converge at the spinneret orifice. After being ejected through circular holes 1 and 2, they form a composite fiber stream with a twin-shaped cross-section. The fiber product of this invention has a twin-core structure, possessing a dense and permanent three-dimensional crimp, and the fabric exhibits good elasticity.

Description

Technical Field

[0001] This invention relates to the field of chemical fiber production technology, and in particular to a heterocomponent bipolyamide fully stretched 3D spring yarn. Background Technology

[0002] In recent years, bicomponent composite self-crimping fibers, as one of the new synthetic fibers, have achieved excellent research and development results in apparel textiles, particularly in wool-like products, and their application areas are constantly expanding. Polyester manufacturers such as DuPont have recently launched the polyester T400 series of bicomponent composite fibers. Polyester T400 is a new type of elastic composite fiber that does not contain spandex yet possesses excellent elasticity. It solves many problems associated with spandex, such as difficulty in dyeing, excessive elasticity, complex weaving, unstable fabric dimensions, and spandex aging during use. However, polyester fabrics have poor moisture absorption, resulting in a stuffy feeling when worn, and are also prone to static electricity and dust accumulation, affecting both aesthetics and comfort.

[0003] Currently, in the preparation process of side-by-side composite fibers, insufficient adhesion at the interface often leads to fiber delamination. Therefore, it is difficult to bond two materials with significant differences in thermal shrinkage in side-by-side composite fibers. If bonded, excessive volume shrinkage of one fiber, due to insufficient adhesion, will cause the two fibers to delaminate. Conventional side-by-side composite fiber assembly designs use two melts extruded from the same spinneret, resulting in poor operability and spinnability. Excessive fusion occurs before the two melts solidify, and the fiber self-crimping effect is weak. Summary of the Invention

[0004] The purpose of this invention is to provide a heterocomponent bipolyamide fully stretched 3D spring yarn with a fine and permanent three-dimensional curl. Due to the different properties of the two raw materials coexisting on the fiber cross section, the shrinkage rate is different, thus a self-curling ability is latent. After heat treatment by GR2 hot roller, it presents a fine and permanent three-dimensional curl.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] A heterocomponent bipolyamide fully stretched 3D spring yarn is formed by combining two halves, consisting of nylon component 1 and nylon component 2, into one piece.

[0007] Specifically, the preparation steps include the following:

[0008] (1) Prepare nylon chips 1, the raw material for nylon component 1, and nylon chips 2, the raw material for nylon component 2;

[0009] (2) Nylon chips 1 and nylon chips 2 are respectively fed into two single-screw extruders to melt and extrude melt 1 and melt 2. After being metered by metering pumps, melt 1 and melt 2 enter the flow guiding assembly. The flow guiding assembly is provided with a type 1 flow guiding channel for melt 1 and a type 2 flow guiding channel for melt 2. After passing through the type 1 flow guiding channel and the type 2 flow guiding channel to balance the pressure, melt 1 and melt 2 reach the spinneret. The front of the spinneret is provided with a type 1 receiving hole for receiving melt 1 and a type 2 receiving hole for receiving melt 2. The type 1 receiving hole and the type 2 receiving hole are set one-to-one. Two corresponding type 1 receiving holes and type 2 receiving holes constitute a set of receiving holes. The back of the spinneret is provided with spinneret holes. The spinneret holes are composed of small-interval round holes 1 and round holes 2. The type 1 receiving holes and type 2 receiving holes of each set of receiving holes are connected to round holes 1 and round holes 2 respectively through obliquely merging channels.

[0010] (3) After melt 1 and melt 2 are ejected through round holes 1 and 2 respectively, they form a composite fiber flow;

[0011] (4) After the composite fiber is cooled by the air cooling equipment, it forms nascent fiber. After being bundled and oiled, the fiber bundle passes through the pre-networker, the first guide roller GR1, the second guide roller GR2 for heat treatment, the main networker, the third guide roller GR3, and finally is wound to form heterocomponent dual polyamide fully stretched 3D spring yarn (FDY).

[0012] In this invention, component 1 and component 2 melts each have independent flow channels, and the two melts do not come into contact before exiting the spinneret orifice. For applications with low viscosity and temperature control requirements, this ensures that the two melts are extruded independently from their respective spinneret orifices. After being guided by four flow guides and balancing the component pressure, the two melts are introduced in parallel into the receiving holes of the spinneret orifice, simultaneously injected at an oblique angle, and converge at the spinneret orifice. After being ejected through circular holes 1 and 2, they form a composite fiber stream with a twin-shaped cross-section.

[0013] Preferably, nylon component 1 is PA6 and nylon component 2 is PA1010. In parallel composite fibers, the two components of the fiber-forming polymer should have similar chemical structures to facilitate the formation of a stable double-sided structure without separation. Once separation occurs, the helical structure of the fiber disappears, and elasticity is lost as well. This is because separation causes the bending stress to disappear; therefore, the two components must have good compatibility. Thus, this invention uses PA6 and PA1010, which have good compatibility, as raw materials.

[0014] Preferably, the flow guiding assembly includes flow guiding plate 1, flow guiding plate 2, flow guiding plate 3 and flow guiding plate 4, which are stacked and sealed together from top to bottom;

[0015] The guide plate 1 is provided with two types of guide holes, namely Type 1 and Type 2, which are the same size and located on both sides of the guide plate 1 and are symmetrically arranged. Both types of guide holes are in the shape of an inverted frustum. Melt 1 and melt 2 enter the guide groove of the guide plate 2 through the two types of guide holes of the guide plate 1, respectively. Both types of guide holes are in the shape of an inverted frustum, which is located in the thickness direction of the guide plate 1.

[0016] The guide plate 2 includes two independent guide channels of type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. The end of the type 1 guide channel is provided with a type 1 guide hole that penetrates the guide plate 2. The end of the type 2 guide channel is provided with a type 2 guide hole that penetrates the guide plate 2. The melt 1 and the melt 2 enter the guide channel of the guide plate 3 through the type 1 guide hole and the type 2 guide hole on the guide plate 2, respectively.

[0017] The guide plate 3 includes two independent types of guide channels: Type 1 and Type 2. The Type 1 guide channel surrounds the Type 2 guide channel. Both Type 1 and Type 2 guide channels are composed of several spaced arc-shaped short guide channels. The arc-shaped short guide channels are arranged in a circular pattern. The ends of the arc-shaped short guide channels of Type 1 guide channels are provided with Type 1 guide holes that penetrate the guide plate 3. The ends of the arc-shaped short guide channels of Type 2 guide channels are provided with Type 2 guide holes that penetrate the guide plate 3. Melt 1 and melt 2 enter the guide channels of the guide plate 4 through the Type 1 guide holes and Type 2 guide holes on the guide plate 3, respectively. The arc-shaped short guide channels are evenly distributed and number 4-6.

[0018] The guide plate 4 includes two independent guide channels, type 1 and type 2, which are arranged in concentric circles. The type 1 guide channel surrounds the type 2 guide channel. The type 1 guide channel has multiple type 1 guide holes that penetrate the guide plate 4, and the type 2 guide channel has multiple type 2 guide holes that penetrate the guide plate 4. The melt 1 and melt 2 enter the spinneret through the type 1 guide holes and type 2 guide holes on the guide plate 4, respectively.

[0019] Preferably, the front side of the spinneret is provided with two independent receiving slots, namely Type 1 and Type 2, which are arranged in concentric circles. Type 1 receiving slots surround Type 2 receiving slots. Type 1 receiving holes and Type 2 receiving holes are evenly distributed on Type 1 and Type 2 receiving slots. The arrangement of receiving slots and receiving holes on the front side of the spinneret corresponds to the arrangement of guiding slots and guiding holes on the guide plate 4.

[0020] This invention designs a unique step-by-step flow-guided self-jetting spinning process. The structure of the flow-guided assembly and spinneret is different from the existing technology. The flow-guided assembly consists of four layers of flow-guided plates stacked and sealed from top to bottom. Each flow-guided plate distributes the flow in steps through the cooperation of flow-guided holes and flow-guided grooves, which can ensure that the melt has a shorter residence time. The melt extruded from each spinneret hole has the same pressure and stable flow distribution, ensuring that the melt has the same residence time and improving the spinnability and uniformity of the fiber.

[0021] Preferably, the melting temperature of the melt in the single-screw extruder is controlled at 250-270℃, and the pressure of the flow guiding component is set at 20-25MPa.

[0022] Preferably, the fineness of the nascent fiber is 20-70D, and the oiling rate of the nascent fiber is 1.6-1.8%.

[0023] Preferably, the number of spinnerets is 12-36; the interval between orifice 1 and orifice 2 is 0.02-0.04 mm. If the interval between the two orifices (orifice 1 and orifice 2) is too large, the two component melts will be difficult to bond together; if the interval is too small, excessive fusion will occur before the two melts solidify, which is difficult to achieve with current processing capabilities and also increases machining costs, making large-scale industrial production difficult. Therefore, the interval between orifice 1 and orifice 2 is controlled to be 0.02-0.04 mm.

[0024] As a preferred option, the air-blowing cooling system uses a ring-blowing system with the following parameters: air temperature 15-19℃, humidity 80-95%, air valve opening 12-28%, air pressure 10-25Pa, and suction pressure -2-10Pa.

[0025] Preferably, the pre-network pressure is controlled at 0.07-0.08 MPa; the main network pressure is controlled at 0.36-0.38 MPa, and the orifice diameter of the network nozzle is 1.3-1.4 mm.

[0026] Preferably, the speed of the first guide roller GR1 is 4000-4300 m / min; the speed of the second guide roller GR2 is 4300-4800 m / min, and the temperature is 130-160℃; the speed of the third guide roller GR3 is 4300-4800 m / min, and the total stretch ratio is controlled at 1.12-1.20.

[0027] The beneficial effects of this invention are:

[0028] In this invention, the two melts follow their respective channels and do not come into contact before exiting the spinneret. This reduces the requirements for viscosity and temperature control, ensuring that the two melts are extruded from their respective spinnerets in their original order. After exiting the spinneret, they form a composite fiber with a twin-shaped cross-section. Due to the different properties of the two raw materials coexisting on the fiber cross-section, their shrinkage rates differ, thus creating a latent self-curling ability. After heat treatment with the GR2 hot roller, this manifests as a fine and permanent three-dimensional crimp.

[0029] This invention employs a ring-shaped airflow cooling system, which provides uniform and consistent cooling for each filament bundle, resulting in better spinnability and making it a key component in the formation of 3D spring yarns. Compared to the open windows of traditional side-blowing systems, the closed airflow of the ring-blowing device ensures maximum airflow utilization, reduces energy consumption, and contributes to energy conservation and environmental protection.

[0030] The heterocomponent bipolyamide fully stretched 3D spring yarn prepared by this invention has a fine and permanent three-dimensional crimp. The fiber product is essentially a fully stretched yarn with the crimp shrinkage rate of elastic fibers, and the fabric has good elasticity. Attached Figure Description

[0031] Figure 1 This is a process flow diagram of the present invention;

[0032] Figure 2 These are structural diagrams of four types of guide plates, where A represents type 1 guide channel, B represents type 2 guide channel, 1-1 is type 1 guide hole, 1-2 is type 1 guide groove, 2-1 is type 2 guide hole, and 2-2 is type 2 guide groove.

[0033] Figure 3 This is a structural diagram of a spinneret, where 3-1 is a type 1 receiving groove, 3-2 is a type 2 receiving groove, 3-3 is a type 1 receiving hole, 3-4 is a type 2 receiving hole, 3-5 is a spinneret hole, 3-6 is round hole 1, and 3-7 is round hole 2.

[0034] Figure 4 This is a schematic diagram of the structure where the type 1 and type 2 receiving holes of the spinneret are obliquely combined to the spinneret hole;

[0035] Figure 5 This is a cross-sectional view of a heterocomponent bipolyamide fully stretched 3D spring wire;

[0036] Figure 6 This is a real image of a heterocomponent bipolyamide fully stretched 3D spring wire, magnified 500 times.

[0037] Figure 7 These are actual photos of the deflector plates and spinnerets (arranged from left to right as deflector plates 1-4 and spinnerets). Detailed Implementation

[0038] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0039] In this invention, unless otherwise specified, all raw materials and equipment used are commercially available or commonly used in the field. Unless otherwise specified, the methods in the following embodiments are conventional methods in the field.

[0040] Example 1:

[0041] A heterocomponent bipolyamide fully stretched 3D spring wire, such as Figure 1 The preparation steps shown are as follows:

[0042] (1) Prepare raw material nylon chips 1 (PA6 chips, constant dull, moisture content <400PPM) for nylon component 1 and raw material nylon chips 2 (PA1010, DuPont, moisture content <400PPM) for nylon component 2.

[0043] (2) Nylon chips 1 and nylon chips 2 are respectively fed into two single-screw extruders and melted at 256°C to extrude melt 1 and melt 2. After being metered by metering pumps, melt 1 and melt 2 enter the flow guiding assembly. The flow guiding assembly is provided with a type 1 flow guiding channel for melt 1 and a type 2 flow guiding channel for melt 2. After passing through the type 1 flow guiding channel and the type 2 flow guiding channel to balance the pressure, melt 1 and melt 2 reach the spinneret. The front of the spinneret is provided with a type 1 receiving channel for melt 1. The receiving holes for receiving melt 2 are of two types: Type 1 and Type 2 receiving holes are arranged in a one-to-one correspondence. Two corresponding Type 1 and Type 2 receiving holes constitute a set of receiving holes. The spinneret has 24 spinneret holes on its reverse side. Each spinneret hole consists of slightly spaced circular holes 1 and 2, with a spacing of 0.02 mm between them. The Type 1 and Type 2 receiving holes in each set are connected to circular holes 1 and 2 respectively through an obliquely merging channel. The pressure set for the flow guiding assembly is 20 MPa.

[0044] The flow guiding assembly includes flow guiding plate 1, flow guiding plate 2, flow guiding plate 3, and flow guiding plate 4, which are stacked and sealed together from top to bottom; for example... Figure 2 , Figure 7 As shown, the guide plate 1 is provided with a type 1 guide hole and a type 2 guide hole that penetrate the guide plate 1. The type 1 guide hole and the type 2 guide hole are the same size. The type 1 guide hole and the type 2 guide hole are located on both sides of the guide plate 1 and are symmetrically arranged. The type 1 guide hole and the type 2 guide hole are both in the shape of an inverted frustum. The melt 1 and the melt 2 enter the guide groove of the guide plate 2 through the type 1 guide hole and the type 2 guide hole of the guide plate 1, respectively.

[0045] The guide plate 2 includes two independent guide channels: a type 1 guide channel and a type 2 guide channel. The type 1 guide channel is in the shape of a double-ring "C" and the type 2 guide channel is in the shape of a "Y". The type 1 guide channel surrounds the type 2 guide channel. The end of the type 1 guide channel is provided with a type 1 guide hole that penetrates the guide plate 2, and the end of the type 2 guide channel is provided with a type 2 guide hole that penetrates the guide plate 2. The melt 1 and the melt 2 enter the guide channel of the guide plate 3 through the type 1 guide hole and the type 2 guide hole on the guide plate 2, respectively.

[0046] The guide plate 3 includes two independent guide channels, type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. Both the type 1 and type 2 guide channels are composed of several spaced arc-shaped short guide channels. The arc-shaped short guide channels are arranged in a circular pattern. The ends of the arc-shaped short guide channels of the type 1 guide channel are provided with type 1 guide holes that penetrate the guide plate 3. The ends of the arc-shaped short guide channels of the type 2 guide channel are provided with type 2 guide holes that penetrate the guide plate 3. The melt 1 and melt 2 enter the guide channels of the guide plate 4 through the type 1 guide holes and type 2 guide holes on the guide plate 3, respectively.

[0047] The guide plate 4 includes two independent guide channels, type 1 and type 2, which are arranged in concentric circles. Type 1 guide channels surround type 2 guide channels. Type 1 guide channels have 24 type 1 guide holes that penetrate the guide plate 4, and type 2 guide channels have 24 type 2 guide holes that penetrate the guide plate 4. Melt 1 and melt 2 enter the spinneret through the type 1 guide holes and type 2 guide holes on the guide plate 4, respectively.

[0048] like Figure 3 As shown, the front of the spinneret is provided with two independent receiving slots, Type 1 and Type 2, which are arranged in concentric circles. Type 1 receiving slots surround Type 2 receiving slots. Type 1 receiving holes and Type 2 receiving holes are evenly distributed on Type 1 and Type 2 receiving slots. The arrangement of receiving slots and receiving holes on the front of the spinneret corresponds to the arrangement of guiding slots and guiding holes on the guide plate 4.

[0049] (3) After melt 1 and melt 2 are ejected through round holes 1 and 2 respectively, they form a composite fiber flow;

[0050] (4) After the composite fiber is cooled by the air blowing cooling equipment, it forms nascent fiber (fineness of 70D). The air blowing cooling is selected by ring blowing, and the parameters are set as follows: air temperature 18.5℃, humidity 93%, air valve opening 15%, air pressure 10Pa, and suction pressure negative 4Pa. After bundling and oiling (oiling rate 1.6%), the fiber bundle passes through the pre-networker (pressure controlled at 0.07Mpa), the first guide roller GR1, the second guide roller GR2 for heat treatment, the main networker (pressure controlled at 0.37Mpa, the orifice diameter of the network nozzle is 1.3mm), the third guide roller GR3, and finally wound to form heterocomponent bicomponent polyamide fully stretched 3D spring yarn (FDY yarn). The speed of the first guide roller GR1 is 4000m / min; the speed of the second guide roller GR2 is 4480m / min, and the temperature is 145℃; the speed of the third guide roller GR3 is 4500m / min, and the total stretch ratio is controlled at 1.12. The cross-section of the heterocomponent bipolyamide fully stretched 3D spring wire is shown in the figure. Figure 5 See 500x magnified micrograph. Figure 6 .

[0051] After exiting the spinneret, the product exhibits different shrinkage rates due to the different properties of the two raw materials coexisting on the fiber cross-section. This results in a latent self-curling ability, which, combined with the support of the GR2 hot roller, results in a fine and permanent three-dimensional curl. The product's curl shrinkage rate is approximately 54%, its breaking strength is 3.95 CN / dtex, its breaking elongation is 32.8%, and its curl stability is 92.8%.

[0052] Comparative Example 1

[0053] Using a conventional parallel composite fiber preparation process, the two components are melted in a single-screw extruder and then metered into a single-channel spinning assembly (i.e., a flow guide assembly). The two components are mixed in the spinning assembly and then extruded through a single-hole spinneret. Other spinning parameters are the same as in Example 1.

[0054] Because the products are fused before exiting the spinneret, although the two raw materials have different properties and will have different shrinkage rates, the potential self-curling ability is greatly reduced due to excessive fusion. After being processed by the GR2 hot roller, the product has a curling effect but it is not obvious, and the curling shrinkage rate is about 15%.

[0055] Example 2:

[0056] A heterocomponent bipolyamide fully stretched 3D spring wire, such as Figure 1 The preparation steps shown are as follows:

[0057] (1) Prepare raw material nylon chips 1 (PA6 chips, constant dull, moisture content <400PPM) for nylon component 1 and raw material nylon chips 2 (PA1010, DuPont, moisture content <400PPM) for nylon component 2.

[0058] (2) Nylon chips 1 and nylon chips 2 are respectively fed into two single-screw extruders and melted at 250°C to extrude melt 1 and melt 2. After being metered by metering pumps, melt 1 and melt 2 enter the flow guiding assembly. The flow guiding assembly is provided with a type 1 flow guiding channel for melt 1 and a type 2 flow guiding channel for melt 2. After passing through the type 1 flow guiding channel and the type 2 flow guiding channel to balance the pressure, melt 1 and melt 2 reach the spinneret. The front of the spinneret is provided with a type 1 receiving channel for melt 1. The receiving holes for receiving melt 2 are of two types: Type 1 and Type 2 receiving holes are arranged in a one-to-one correspondence. Two corresponding Type 1 and Type 2 receiving holes constitute a set of receiving holes. The spinneret has 12 spinneret holes on its reverse side. Each spinneret hole consists of slightly spaced circular holes 1 and 2, with a spacing of 0.04 mm between them. The Type 1 and Type 2 receiving holes in each set are connected to circular holes 1 and 2 respectively through an obliquely merging channel. The pressure set for the flow guiding assembly is 25 MPa.

[0059] The flow guiding assembly includes flow guiding plate 1, flow guiding plate 2, flow guiding plate 3, and flow guiding plate 4, which are stacked and sealed together from top to bottom; for example... Figure 2 , Figure 7 As shown, the guide plate 1 is provided with a type 1 guide hole and a type 2 guide hole that penetrate the guide plate 1. The type 1 guide hole and the type 2 guide hole are the same size. The type 1 guide hole and the type 2 guide hole are located on both sides of the guide plate 1 and are symmetrically arranged. The type 1 guide hole and the type 2 guide hole are both in the shape of an inverted frustum. The melt 1 and the melt 2 enter the guide groove of the guide plate 2 through the type 1 guide hole and the type 2 guide hole of the guide plate 1, respectively.

[0060] The guide plate 2 includes two independent guide channels of type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. The end of the type 1 guide channel is provided with a type 1 guide hole that penetrates the guide plate 2. The end of the type 2 guide channel is provided with a type 2 guide hole that penetrates the guide plate 2. The melt 1 and the melt 2 enter the guide channel of the guide plate 3 through the type 1 guide hole and the type 2 guide hole on the guide plate 2, respectively.

[0061] The guide plate 3 includes two independent guide channels, type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. Both the type 1 and type 2 guide channels are composed of several spaced arc-shaped short guide channels. The arc-shaped short guide channels are arranged in a circular pattern. The ends of the arc-shaped short guide channels of the type 1 guide channel are provided with type 1 guide holes that penetrate the guide plate 3. The ends of the arc-shaped short guide channels of the type 2 guide channel are provided with type 2 guide holes that penetrate the guide plate 3. The melt 1 and melt 2 enter the guide channels of the guide plate 4 through the type 1 guide holes and type 2 guide holes on the guide plate 3, respectively.

[0062] The guide plate 4 includes two independent guide channels, type 1 and type 2, which are arranged in concentric circles. Type 1 guide channels surround type 2 guide channels. Type 1 guide channels have 12 type 1 guide holes that penetrate the guide plate 4, and type 2 guide channels have 12 type 2 guide holes that penetrate the guide plate 4. Melt 1 and melt 2 enter the spinneret through the type 1 guide holes and type 2 guide holes on the guide plate 4, respectively.

[0063] like Figure 3 As shown, the front of the spinneret is provided with two independent receiving slots, Type 1 and Type 2, which are arranged in concentric circles. Type 1 receiving slots surround Type 2 receiving slots. Type 1 receiving holes and Type 2 receiving holes are evenly distributed on Type 1 and Type 2 receiving slots. The arrangement of receiving slots and receiving holes on the front of the spinneret corresponds to the arrangement of guiding slots and guiding holes on the guide plate 4.

[0064] (3) After melt 1 and melt 2 are ejected through round holes 1 and 2 respectively, they form a composite fiber flow;

[0065] (4) After the composite fiber is cooled by the air blowing cooling equipment, it forms nascent fiber (fineness of 20D). The air blowing cooling is selected by ring blowing, and the parameters are set as follows: air temperature 15℃, humidity 80%, air valve opening 12%, air pressure 25Pa, suction pressure negative 2Pa. After bundling and oiling (oiling rate 1.8%), the fiber bundle passes through the pre-networker (pressure controlled at 0.08Mpa), the first guide roller GR1, the second guide roller GR2 for heat treatment, the main networker (pressure controlled at 0.38Mpa, network nozzle orifice diameter of 1.4mm), the third guide roller GR3, and finally wound to form heterocomponent bicomponent polyamide fully stretched 3D spring yarn (FDY yarn). The speed of the first guide roller GR1 is 4150m / min; the speed of the second guide roller GR2 is 4300m / min, and the temperature is 130℃; the speed of the third guide roller GR3 is 4300m / min, and the total stretch ratio is controlled at 1.15.

[0066] After exiting the spinneret, the product exhibits different shrinkage rates due to the different properties of the two raw materials coexisting on the fiber cross-section. This results in a latent self-curling ability, which, combined with the support of the GR2 hot roller, creates a fine and permanent three-dimensional curl. The product's curling shrinkage rate is approximately 44%.

[0067] Example 3:

[0068] A heterocomponent bipolyamide fully stretched 3D spring wire, such as Figure 1 The preparation steps shown are as follows:

[0069] (1) Prepare raw material nylon chips 1 (PA6 chips, constant dull, moisture content <400PPM) for nylon component 1 and raw material nylon chips 2 (PA1010, DuPont, moisture content <400PPM) for nylon component 2.

[0070] (2) Nylon chips 1 and nylon chips 2 are respectively fed into two single-screw extruders and melted at 270°C to extrude melt 1 and melt 2. After being metered by metering pumps, melt 1 and melt 2 enter the flow guiding assembly. The flow guiding assembly is provided with a type 1 flow guiding channel for melt 1 and a type 2 flow guiding channel for melt 2. After passing through the type 1 flow guiding channel and the type 2 flow guiding channel to balance the pressure, melt 1 and melt 2 reach the spinneret. The front of the spinneret is provided with a type 1 receiving channel for melt 1. The receiving holes for receiving melt 2 are of two types: Type 1 and Type 2 receiving holes are arranged in a one-to-one correspondence. Two corresponding Type 1 and Type 2 receiving holes constitute a set of receiving holes. The spinneret has 36 spinneret holes on its reverse side. Each spinneret hole consists of slightly spaced circular holes 1 and 2, with a spacing of 0.03 mm between them. The Type 1 and Type 2 receiving holes in each set are connected to circular holes 1 and 2 respectively through an obliquely merging channel. The pressure set for the flow guiding assembly is 22 MPa.

[0071] The flow guiding assembly includes flow guiding plate 1, flow guiding plate 2, flow guiding plate 3, and flow guiding plate 4, which are stacked and sealed together from top to bottom; for example... Figure 2 , Figure 7 As shown, the guide plate 1 is provided with a type 1 guide hole and a type 2 guide hole that penetrate the guide plate 1. The type 1 guide hole and the type 2 guide hole are the same size. The type 1 guide hole and the type 2 guide hole are located on both sides of the guide plate 1 and are symmetrically arranged. The type 1 guide hole and the type 2 guide hole are both in the shape of an inverted frustum. The melt 1 and the melt 2 enter the guide groove of the guide plate 2 through the type 1 guide hole and the type 2 guide hole of the guide plate 1, respectively.

[0072] The guide plate 2 includes two independent guide channels of type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. The end of the type 1 guide channel is provided with a type 1 guide hole that penetrates the guide plate 2. The end of the type 2 guide channel is provided with a type 2 guide hole that penetrates the guide plate 2. The melt 1 and the melt 2 enter the guide channel of the guide plate 3 through the type 1 guide hole and the type 2 guide hole on the guide plate 2, respectively.

[0073] The guide plate 3 includes two independent guide channels, type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. Both the type 1 and type 2 guide channels are composed of several spaced arc-shaped short guide channels. The arc-shaped short guide channels are arranged in a circular pattern. The ends of the arc-shaped short guide channels of the type 1 guide channel are provided with type 1 guide holes that penetrate the guide plate 3. The ends of the arc-shaped short guide channels of the type 2 guide channel are provided with type 2 guide holes that penetrate the guide plate 3. The melt 1 and melt 2 enter the guide channels of the guide plate 4 through the type 1 guide holes and type 2 guide holes on the guide plate 3, respectively.

[0074] The guide plate 4 includes two independent guide channels, type 1 and type 2, which are arranged in concentric circles. Type 1 guide channels surround type 2 guide channels. Type 1 guide channels have 36 type 1 guide holes that penetrate the guide plate 4, and type 2 guide channels have 36 type 2 guide holes that penetrate the guide plate 4. Melt 1 and melt 2 enter the spinneret through the type 1 guide holes and type 2 guide holes on the guide plate 4, respectively.

[0075] like Figure 3 As shown, the front of the spinneret is provided with two independent receiving slots, Type 1 and Type 2, which are arranged in concentric circles. Type 1 receiving slots surround Type 2 receiving slots. Type 1 receiving holes and Type 2 receiving holes are evenly distributed on Type 1 and Type 2 receiving slots. The arrangement of receiving slots and receiving holes on the front of the spinneret corresponds to the arrangement of guiding slots and guiding holes on the guide plate 4.

[0076] (3) After melt 1 and melt 2 are ejected through round holes 1 and 2 respectively, they form a composite fiber flow;

[0077] (4) After the composite fiber is cooled by the air blowing cooling equipment, it forms nascent fiber (fineness of 50D). The air blowing cooling is selected by ring blowing, and the parameters are set as follows: air temperature 19℃, humidity 95%, air valve opening 28%, air pressure 20Pa, suction pressure negative 10Pa; after bundling and oiling (oiling rate 1.7%), the fiber bundle passes through the pre-networker (pressure controlled at 0.075Mpa), the first guide roller GR1, the second guide roller GR2 for heat treatment, the main networker (pressure controlled at 0.36Mpa, the orifice diameter of the network nozzle is 1.35mm), the third guide roller GR3, and finally wound to form heterocomponent bicomponent polyamide fully stretched 3D spring yarn (FDY yarn); the speed of the first guide roller GR1 is 4300m / min; the speed of the second guide roller GR2 is 4800m / min, and the temperature is 160℃; the speed of the third guide roller GR3 is 4800m / min, and the total stretch ratio is controlled at 1.20.

[0078] After exiting the spinneret, the product exhibits different shrinkage rates due to the different properties of the two raw materials coexisting on the fiber cross-section. This results in a latent self-curling ability, which, combined with the support of the GR2 hot roller, produces a fine and permanent three-dimensional curl. The product's curling shrinkage rate is approximately 50%.

[0079] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Other variations and modifications are possible without departing from the technical solutions described in the claims.

Claims

1. A heterocomponent bilayer polyamide fully stretched 3D spring wire, characterized in that, The two halves, composed of nylon component 1 and nylon component 2, are combined into one piece. Specifically, the preparation steps include the following: (1) Prepare nylon chips 1, the raw material for nylon component 1, and nylon chips 2, the raw material for nylon component 2; (2) Nylon chips 1 and nylon chips 2 are respectively fed into two single-screw extruders to melt and extrude melt 1 and melt 2. After being metered by metering pumps, melt 1 and melt 2 enter the flow guiding assembly. The flow guiding assembly is provided with a type 1 flow guiding channel for melt 1 and a type 2 flow guiding channel for melt 2. After passing through the type 1 flow guiding channel and the type 2 flow guiding channel to balance the pressure, melt 1 and melt 2 reach the spinneret. The front of the spinneret is provided with a type 1 receiving hole for receiving melt 1 and a type 2 receiving hole for receiving melt 2. The type 1 receiving hole and the type 2 receiving hole are set one-to-one. Two corresponding type 1 receiving holes and type 2 receiving holes constitute a set of receiving holes. The back of the spinneret is provided with spinneret holes. The spinneret holes are composed of small-interval round holes 1 and round holes 2. The type 1 receiving holes and type 2 receiving holes of each set of receiving holes are connected to round holes 1 and round holes 2 respectively through obliquely merging channels. (3) After melt 1 and melt 2 are ejected through round holes 1 and 2 respectively, they form a composite fiber flow; (4) After the composite fiber is cooled by the air cooling equipment, it forms nascent fiber. After being bundled and oiled, the fiber bundle passes through the pre-networker, the first guide roller GR1, the second guide roller GR2 for heat treatment, the main networker, the third guide roller GR3, and finally is wound to form a heterogeneous dual polyamide fully stretched 3D spring wire. The nylon component 1 is PA6, and the nylon component 2 is PA1010; The flow guiding assembly includes flow guiding plate 1, flow guiding plate 2, flow guiding plate 3 and flow guiding plate 4, which are stacked and sealed together from top to bottom; The guide plate 1 is provided with a type 1 guide hole and a type 2 guide hole that penetrate the guide plate 1. The type 1 guide hole and the type 2 guide hole are the same size. The type 1 guide hole and the type 2 guide hole are located on both sides of the guide plate 1 and are symmetrically arranged. Both the type 1 guide hole and the type 2 guide hole are in the shape of an inverted frustum. The melt 1 and the melt 2 enter the guide groove of the guide plate 2 through the type 1 guide hole and the type 2 guide hole of the guide plate 1, respectively. The guide plate 2 includes two independent guide channels of type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. The end of the type 1 guide channel is provided with a type 1 guide hole that penetrates the guide plate 2. The end of the type 2 guide channel is provided with a type 2 guide hole that penetrates the guide plate 2. The melt 1 and the melt 2 enter the guide channel of the guide plate 3 through the type 1 guide hole and the type 2 guide hole on the guide plate 2, respectively. The guide plate 3 includes two independent guide channels, type 1 and type 2. The type 1 guide channel surrounds the type 2 guide channel. Both the type 1 and type 2 guide channels are composed of several spaced arc-shaped short guide channels. The arc-shaped short guide channels are arranged in a circular pattern. The ends of the arc-shaped short guide channels of the type 1 guide channel are provided with type 1 guide holes that penetrate the guide plate 3. The ends of the arc-shaped short guide channels of the type 2 guide channel are provided with type 2 guide holes that penetrate the guide plate 3. The melt 1 and melt 2 enter the guide channels of the guide plate 4 through the type 1 guide holes and type 2 guide holes on the guide plate 3, respectively. The guide plate 4 includes two independent guide channels, type 1 and type 2, which are arranged in concentric circles. The type 1 guide channel surrounds the type 2 guide channel. The type 1 guide channel has multiple type 1 guide holes that penetrate the guide plate 4, and the type 2 guide channel has multiple type 2 guide holes that penetrate the guide plate 4. The melt 1 and melt 2 enter the spinneret through the type 1 guide holes and type 2 guide holes on the guide plate 4, respectively. The front of the spinneret is provided with two independent receiving slots, Type 1 and Type 2, which are arranged in concentric circles. Type 1 receiving slots surround Type 2 receiving slots. Type 1 receiving holes and Type 2 receiving holes are evenly distributed on Type 1 and Type 2 receiving slots. The arrangement of receiving slots and receiving holes on the front of the spinneret corresponds to the arrangement of guiding slots and guiding holes on the guide plate 4. The number of spinnerets is 12-36; the interval between round hole 1 and round hole 2 is 0.02-0.04 mm.

2. The heterocomponent bilayer polyamide fully stretched 3D spring wire according to claim 1, characterized in that, The melting temperature of the melt in the single-screw extruder is controlled at 250-270℃, and the pressure of the flow guiding component is set at 20-25MPa.

3. The heterocomponent bilayer polyamide fully stretched 3D spring wire according to claim 1, characterized in that, The fineness of the nascent fiber is 20-70D, and the oiling rate of the nascent fiber is 1.6-1.8%.

4. The heterocomponent bilayer polyamide fully stretched 3D spring wire according to claim 1, characterized in that, For air cooling, select ring air blowing with the following parameters: air temperature 15-19℃, humidity 80-95%, air valve opening 12-28%, air pressure 10-25Pa, and suction pressure -2-10Pa.

5. The heterocomponent bilayer polyamide fully stretched 3D spring wire according to claim 1, characterized in that, The pre-network pressure is controlled at 0.07-0.08 MPa; the main network pressure is controlled at 0.36-0.38 MPa, and the orifice diameter of the network nozzle is 1.3-1.4 mm.

6. The heterocomponent bilayer polyamide fully stretched 3D spring wire according to claim 1, characterized in that, The speed of the first guide roller GR1 is 4000-4300 m / min; the speed of the second guide roller GR2 is 4300-4800 m / min, and the temperature is 130-160℃; the speed of the third guide roller GR3 is 4300-4800 m / min, and the total stretch ratio is controlled at 1.12-1.20.

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