Deformation device and deformation method

Abstract

This invention relates to a deformation apparatus for producing crimped plastic filaments, comprising a deformation nozzle having a nozzle insert with a compressed hot air supply port and a guide tube, and a cooling mechanism, wherein the cooling mechanism is a reverse airflow mechanism integrated within the deformation nozzle. The invention also relates to a deformation method for producing crimped plastic filaments, wherein at least one plastic filament is blown through the nozzle insert in a conveying direction by a compressed hot air flow in the deformation nozzle and crimped within a guide tube adjacent to the nozzle insert, and subsequently the at least one crimped plastic filament is cooled, wherein the at least one crimped plastic filament is cooled such that a reverse airflow, at least partially oriented opposite to the compressed hot air flow and colder than the compressed hot air flow, is guided toward the at least one crimped plastic filament. According to the invention, the reverse airflow mechanism includes a cold air supply port, wherein a reverse airflow tube aligned with the guide tube is arranged between the cold air supply port and the guide tube, and wherein a through nozzle is arranged between the reverse airflow tube and the cold air supply port.

Description

Technical Field

[0001] This invention relates to a deformation apparatus for producing crimped plastic filaments, comprising a deformation nozzle having a nozzle insert with a compressed hot air supply port and a guide tube, and a cooling mechanism, wherein the cooling mechanism is a reverse airflow mechanism integrated into the deformation nozzle. The invention also relates to a deformation method for producing crimped plastic filaments, wherein at least one plastic filament is blown through the nozzle insert in the deformation nozzle by a compressed hot airflow in a conveying direction and deformed within a guide tube adjacent to the nozzle insert, and subsequently the at least one crimped plastic filament is cooled, wherein the at least one crimped plastic filament is cooled such that a reverse airflow, at least partially oriented opposite to and cooler than the compressed hot airflow, is guided toward the at least one crimped plastic filament.

[0002] The crimping of the plastic filaments or threads described in this invention is also commonly referred to as the deformation of plastic filaments or threads in textile technology. Background Technology

[0003] For example, in the production of artificial grass, crimped plastic filaments or crimped plastic threads are used. Here, in various types of artificial grass, crimped plastic threads (called moss fibers) are added as filler in the bottom area between the upright, long grass blades formed from smooth plastic threads. This results in a very soft and compact structure in which the long blades of grass are supported by the crimped threads.

[0004] Document DE2457825A1 discloses a coiling device with a cylindrical filling chamber. The coiling device is equipped with an inlet for a hot medium and four narrow pipes. These four pipes are arranged such that turbulence of the hot medium occurs in a diffusion chamber. The filling chamber has a hemispherical inlet end and is equipped with multiple radially extending openings to allow the medium to escape.

[0005] A yarn crimping device, as known from document DE2903508A1, includes a nozzle unit for a hot medium, a filling chamber with a hot medium outlet, a residence time control chamber with a cold medium outlet mechanism, and a mixing nozzle. The nozzle unit is connected to a filling chamber housing, which is composed of radially extending rib assemblies. The hot medium can flow radially out through the gaps between adjacent ribs.

[0006] A similar crimping device is described in document DE2753618A1. There, the yarn passes through an inlet, after which a processing nozzle is provided, having a central channel and four channels arranged tangentially thereafter. The yarn is swirled with fluid and fed along the channels into a relaxation chamber equipped with multiple orifices through which fluid is released to the atmosphere. The device has a second nozzle to provide fluid for suppressing and cooling the yarn.

[0007] Document DE102007022112A1 discloses an apparatus for crimping synthetic filaments. The apparatus has a deformation nozzle in which a bundle of filaments is confined under the action of hot air guided through the deformation nozzle. Due to the heat, the filaments form loops and arc segments, thereby forming a filament plug in the filling chamber of the deformation nozzle. The filaments, also heated and thus deformed in loop form, are compressed at the filament plug, resulting in filament crimping.

[0008] In an improved version of a known deformable nozzle, instead of a filling chamber, a guide tube is provided through which the hot filaments are guided. The compressed hot air blowing the filaments through the deformable nozzle is abruptly exhausted through the guide tube. Due to its nature, the guide tube still holds the filament bundle together. An interruption occurs in the guide tube region, causing the individual filaments to suddenly loosen and curl.

[0009] In both of the aforementioned known deformation devices, cooling cylinders with ventilated guide sleeves are arranged below the deformation nozzles, creating a negative pressure within these cylinders. Due to the continued flow of air from the deformation nozzles and the suction effect of the cooling cylinders generated by the negative pressure, the coiled filaments from the deformation nozzles are placed in multiple loops on tracks formed on the guide sleeves of the cooling cylinders. Because the rotational speed of the cooling cylinders is lower than the feed speed of the filaments from the deformation nozzles, the filaments retain their coiled shape, and the coiling is fixed by cooling.

[0010] In traditional deformation devices, a rotating cooling cylinder, along with a vacuum chamber located within it, ensures the accumulation, cooling, and precise point-by-point removal of the deformed monofilaments.

[0011] Then, the crimped filaments are drawn into crimped yarns by a drawing device, such as a guide disc, located downstream of the cooling cylinder.

[0012] At the end of the process, the curled yarn is wound onto the winding head.

[0013] For example, in practice, these crimped threads are often heat-treated again before being used in the production of artificial grass, thereby further strengthening the crimp and shortening the threads.

[0014] In known crimped filament production, the high energy consumption caused by the cooling cylinder is particularly problematic. For it to function, the cooling cylinder requires a vacuum, which must be generated by a compressor. Furthermore, the cylinder and compressor require considerable space. Summary of the Invention

[0015] Therefore, the object of the present invention is to provide a deformation apparatus and deformation method for producing crimped plastic filaments, thereby saving energy and installation space.

[0016] On one hand, this objective is achieved by a deformation device for producing crimped plastic filaments, the deformation device comprising a deformation nozzle having a nozzle insert and a cooling mechanism, the nozzle insert having a compressed hot air supply port and a guide tube, wherein the cooling mechanism is a reverse airflow mechanism integrated into the deformation nozzle, wherein the reverse airflow mechanism includes a cold air supply interface, wherein a reverse airflow slit tube aligned with the guide tube is arranged between the cold air supply interface and the guide tube, and wherein a through nozzle is arranged between the reverse airflow slit tube and the cold air supply interface.

[0017] The device according to the invention does not require a cooling cylinder. Instead, the device according to the invention has a reverse airflow mechanism integrated as a cooling mechanism into the deformable nozzle. In this invention, compared with the prior art, installation space and energy are saved due to the absence of a cooling cylinder.

[0018] In a nozzle insert of a deformable nozzle that is circumferentially closed except for the compressed hot air supply port, at least one plastic filament is intensely heated by a flow of hot air generated by the compressed hot air supply port in the deformable nozzle, causing the at least one plastic filament to form a loop. Simultaneously, the at least one thermoplastic filament is conveyed to a guide tube via compressed hot air.

[0019] In the guide wire tube adjacent to the nozzle insert, as described above, at least one plastic filament, intensely heated by compressed hot air, is coiled by a sudden interruption of flow.

[0020] The guide wire slot tube preferably has a longitudinal slot, through which hot air entering the guide wire slot tube from the nozzle insert can escape along the delivery direction of the deformable nozzle.

[0021] Simultaneously, at least one crimped plastic filament is conveyed by an airflow of compressed hot air in the direction of a reverse airflow generated by a reverse airflow mechanism. In this invention, at least one crimped plastic filament is cooled within a deformation nozzle by a reverse airflow oriented opposite to the compressed hot airflow, thereby fixing the crimp.

[0022] Furthermore, the reverse airflow causes a slight deceleration and subsequent compression of at least one coiled plastic filament at the point where the reverse airflow meets the compressed hot airflow, resulting in further reinforcement of the coil.

[0023] In the device according to the invention, the reverse airflow mechanism includes a cold air supply interface, wherein a reverse airflow slit tube aligned with and engaged with the guide wire slit tube is arranged between the cold air supply interface and the guide wire slit tube.

[0024] According to the invention, the at least one crimped plastic filament enters a reverse airflow slit tube after exiting the guide filament slit tube, where it encounters the reverse airflow in bundle form. The reverse airflow slows down the at least one crimped plastic filament, which further enhances its compression and crimping, while simultaneously causing it to cool. Due to cooling, the crimping solidifies.

[0025] Because the reverse airflow slit tube has slots, preferably longitudinal slots, a portion of the reverse airflow escapes from it. The reverse airflow consists of air that is cooler than the compressed hot air. Since the compressed hot air, which has not escaped from the guide wire slit tube and is slightly cooled but still warm, is blown in the opposite direction of the reverse airflow, the reverse airflow is least cold at the beginning of the reverse airflow slit tube, i.e., near the guide wire slit tube, and becomes increasingly colder along the reverse airflow slit tube until it reaches the cold air supply interface. This results in the gradual solidification of the curled plastic filament within the reverse airflow slit tube.

[0026] Particularly advantageous is that at least one heated guide disc, which can be used to preheat at least one plastic filament, is arranged before the deformation nozzle in the filament processing direction of the deformation device. It has been shown that, in this invention, a single such heated guide disc is sufficient to achieve advantageous preheating of at least one plastic filament. This saves considerable installation space.

[0027] This objective is also achieved by a deformation method for producing crimped plastic filaments, wherein at least one plastic filament is blown in the conveying direction by a compressed hot airflow through a nozzle insert in a deformation nozzle and crimped in a guide tube adjacent to the nozzle insert, wherein at least one crimped plastic filament is cooled such that a reverse airflow, at least partially opposite in orientation to the hot compressed airflow and colder than the hot compressed airflow, is guided toward at least one crimped plastic filament, wherein the reverse airflow is guided onto at least one crimped plastic filament by a reverse airflow slit tube aligned with and engaged with the guide tube, and wherein at least one crimped plastic filament is drawn through the reverse airflow slit tube by a through nozzle located downstream of the reverse airflow slit tube in the conveying direction and blowing air in the conveying direction.

[0028] In the method of the present invention, the cooling cylinder used to cool at least one plastic filament coiled in the deformation nozzle is eliminated. Therefore, the method of the present invention can be performed on a deformation device that consumes very little energy and requires very little space. The method of the present invention also eliminates the high maintenance costs associated with the cooling cylinders used in existing methods.

[0029] In the method according to the invention, not only does the curling of at least one plastic filament occur in the deforming nozzle, but its cooling also occurs, and thus the curling is fixed.

[0030] In the method of the present invention, the at least one plastic filament is first heated in a preferably tubular nozzle insert by a flow of compressed hot air, which is longitudinally closed except for the compressed hot air supply port. In a guide tube preferably longitudinally slotted in a deformable nozzle, the at least one plastic filament is coiled by a sudden interruption of flow.

[0031] The at least one curled plastic filament then encounters a reverse airflow, which is directed in the opposite direction to the conveying direction toward the at least one curled plastic filament, cooling the filament and thus solidifying its curl.

[0032] According to the invention, a reverse airflow is guided through a reverse airflow slit tube to at least one crimped plastic filament, which is aligned and engaged with and connected to a guide filament slit tube. The at least one crimped plastic filament can be further guided through the reverse airflow slit tube within the filament bundle, wherein the reverse airflow can thus be directed simultaneously to the at least one crimped plastic filament in a targeted manner. Due to the slotted design of the reverse airflow slit tube, cold air exits from there in the reverse direction of transport. As a result, the temperature difference between the compressed hot air and the at least one crimped plastic filament transported to the reverse airflow slit tube, as well as the intensity of the cold air at the transition from the guide filament slit tube to the reverse airflow slit tube, remains moderate compared to the other end of the reverse airflow slit tube, thereby allowing the at least one crimped plastic filament to gradually cool and solidify within the reverse airflow slit tube.

[0033] Since the deformation nozzle in the deformation method according to the invention undertakes the winding and cooling of at least one coiled plastic filament, the deformation method of the present invention is substantially more economical than the known deformation methods described above. The deformation nozzle formed according to the invention occupies much less installation space and consumes much less energy than the combination of a deformation nozzle and a cooling cylinder that is only suitable for winding.

[0034] However, the deformed filaments produced using the deformation method according to the present invention are essentially equivalent to conventional deformed filaments.

[0035] According to the invention, at least one crimped plastic filament is drawn through a through-nozzle, which blows air in the conveying direction downstream of the reverse airflow slit tube and in the conveying direction of the deforming nozzle. The through-nozzle creates an airflow oriented in the conveying direction, which conveys at least one crimped plastic filament in the direction of the outlet tube or the discharge end of the deforming nozzle, despite the reverse airflow. This method prevents at least one crimped plastic filament from stagnating or accumulating within the deforming nozzle.

[0036] If at least one plastic filament is preheated by a single heated guide roller before being guided through the deformation nozzle, the method of the present invention can be implemented very efficiently in a particularly compact device with reduced operating costs.

[0037] In a simple yet efficient embodiment of the method of the present invention, the reverse airflow is at ambient pressure. Attached Figure Description

[0038] The preferred embodiments of the present invention, their structure, function, and advantages are explained in more detail below with reference to the figures, wherein:

[0039] Figure 1 An embodiment of the deformation nozzle of the deformation device of the present invention is schematically shown in a sectional side view; and

[0040] Figure 2 Schematic illustration in non-sectioned side view Figure 1 Deformed nozzle. Detailed Implementation

[0041] Figure 1 and Figure 2 A possible embodiment of the deformable nozzle 1 according to the present invention is shown.

[0042] In its conveying direction A, the deformable nozzle 1 includes, one after another, a nozzle needle 2, a nozzle insert 3 with a compressed hot air supply port 4 located thereon, a guide wire slit tube 5, a reverse air flow slit tube 6, a through nozzle 7, a cold air supply interface 8, and an outlet pipe 9.

[0043] The nozzle insert 3 is the internal hollow area of ​​the deformable nozzle 1, and is circumferentially closed except for the compressed hot air supply port 4. Accordingly, at least one plastic filament, preferably a bundle of many plastic filaments, can be heated or kept warm within the nozzle insert 3. Heating or warming is achieved by compressed hot air flowing into the nozzle insert 3 from the compressed hot air supply port 4. A compressed hot air flow B is generated in the nozzle insert 3 through the compressed hot air supply port 4, flowing in the delivery direction A of the deformable nozzle 1. The pressure of the compressed hot air flow B is, for example, in the range of 5 to 6 bar, and the temperature is in the range of 100°C to 150°C or 120°C to 130°C.

[0044] The guide wire tube 5 is mechanically connected to the nozzle insert 3 in such a way that at least one warm plastic filament can directly enter the guide wire tube 5 from the nozzle insert 3. The guide wire tube 5 is also hollow inside, but has slots on its circumference so that air can escape.

[0045] The guide wire slot 5 is connected to the reverse airflow slot 6 via the connector 10, so that their axes of rotation are aligned. The reverse airflow slot 6 is also hollow on the inside and has slots on its circumference, allowing air to exit through it as well.

[0046] One end of the reverse airflow slit tube 6, which is positioned opposite the guide wire slit tube 5, is mechanically connected to the connecting block 11 of the deformable nozzle 1. The connecting block 11 includes a guide wire channel 12 on its inner side, and is first connected to the through nozzle 7 in the conveying direction of the deformable nozzle 1, followed by the cold air supply interface 8.

[0047] The airflow C entering the wire guide channel 12 from the through nozzle 7 is oriented at least partially in the delivery direction A. The reverse airflow D entering the wire guide channel 12 from the cold air supply interface 8 is oriented at least partially opposite to the delivery direction A, and therefore at least partially against the compressed hot airflow B.

[0048] The air flowing into the guide wire channel 12 from the through nozzle 7 and the air flowing into the guide wire channel 12 from the cold air supply port 8 are both much colder than the compressed hot air flow B. The air from the cold air supply port 8, or the resulting reverse air flow D, can be at ambient pressure, i.e., 1 bar.

[0049] At least one plastic filament, preferably multiple plastic monofilaments forming a bundle and introduced into the deformation nozzle 1, such as eight plastic monofilaments, are pre-generated by a monofilament extrusion device, optionally pass through a water bath, and are then pulled by at least one, preferably a single, heated guide disc pair, thereby being heated and subjected to a certain stress, and then supplied directly to the deformation nozzle, which is usually located below the heated guide disc pair, while still hot and soft.

[0050] At least one plastic filament can be made of, for example, LDPE (low-density polyethylene) or PP (polypropylene), and many other plastic materials can also be used for this purpose.

[0051] The at least one plastic filament is blown through the deformable nozzle 1 at a high air pressure typically greater than 5 bar and a high temperature, depending on the material but typically greater than 100°C. The high-pressure and high-temperature air is generated by a compressed hot air supply port 4 connected to the nozzle insert 3.

[0052] Compressed hot air is suddenly discharged to the outside through the guide wire slit tube 5 located at the outlet of the nozzle insert 3. The discharge of compressed hot air occurs uniformly along the longitudinal slit of the guide wire slit tube 5. Nevertheless, at least one plastic filament or bundle remains together within the guide wire slit tube 5. A flow interruption occurs within the guide wire slit tube 5, and at least one plastic filament or bundle of filaments suddenly slackens and curls.

[0053] Through the compressed hot air supply port 4, at least one coiled plastic filament is further propelled by the continuing airflow, and it directly encounters the ambient air in the opposite airflow D. The at least one coiled plastic filament is slowed and cooled in the opposite airflow.

[0054] In a further step of the deformation method, the guide disc further feeds at least one coiled plastic filament to the winding machine. The at least one coiled plastic filament is further cooled in the path between the nozzle outlet 13 of the deformation nozzle 1 and the guide disc.

[0055] The guide disc is generally not heated and the filament is drawn and wound at a very low tension, for example, at a speed of about 100 meters per minute.

[0056] Then, the deformed yarn is wound onto the winding head by a winding machine.

[0057] Multiple deformation nozzles 1 can be arranged side by side on the deformation device according to the invention, so that multiple filament bundles can be deformed at the same time.

[0058] In the deformation device according to the invention, the temperature, air pressure and filament speed or wire speed are precisely set and coordinated with each other, so there is no blockage in the deformation nozzle 1.

Claims

1. A deformation apparatus for producing crimped plastic filaments, the deformation apparatus comprising a deformation nozzle (1) and a cooling mechanism located within the deformation nozzle (1), the deformation nozzle (1) having a nozzle insert (3), a guide filament slit tube (5) connected downstream of the nozzle insert (3), and a through nozzle (7), the nozzle insert (3) having a compressed hot air supply port (4), wherein, The cooling mechanism is a reverse airflow mechanism integrated into the deformable nozzle (1), characterized in that the reverse airflow mechanism includes a cold air supply interface (8) and a reverse airflow slit tube (6), wherein the reverse airflow slit tube (6), aligned with the guide wire slit tube (5), is arranged between the cold air supply interface (8) and the guide wire slit tube (5), and wherein a through nozzle (7) is arranged between the reverse airflow slit tube (6) and the cold air supply interface (8), wherein the deformable nozzle (1) It also includes a wire guide channel (12), which is first connected to the wire guide channel (12) in the delivery direction (A) of the deformable nozzle (1) by the through nozzle (7) and then by the cold air supply interface (8), wherein the airflow (C) entering the wire guide channel (12) from the through nozzle (7) is oriented at least partially in the delivery direction (A), and the reverse airflow (D) entering the wire guide channel (12) from the cold air supply interface (8) is oriented at least partially opposite to the delivery direction (A).

2. The apparatus of claim 1 wherein In the filament processing direction of the deformation device, a separate heated guide disc pair is arranged in front of the deformation nozzle (1).

3. A texturing method for producing crimped plastic filaments by means of a texturing device according to claim 1, wherein, At least one plastic filament is blown through a nozzle insert (3) in the conveying direction (A) by a compressed hot air flow (B) in a deforming nozzle (1) and coiled within a guide filament slot (5) adjacent to the nozzle insert (3). Subsequently, the at least one coiled plastic filament is cooled such that a counter-airflow (D), at least partially oriented opposite to the compressed hot air flow (B), is guided toward the at least one coiled plastic filament. The counter-airflow (D) is colder than the compressed hot air flow (B). The counter-airflow (D) is characterized by being guided onto the at least one coiled plastic filament via a counter-airflow slot (6) aligned with and connected to the guide filament slot (5). The at least one coiled plastic filament is then cooled. The filament is drawn through the reverse airflow slit tube (6) via a through nozzle (7), the through nozzle (7) being located downstream of the reverse airflow slit tube (6) in the conveying direction (A) and blowing air in the conveying direction (A). The deformable nozzle (1) also includes a guide channel (12). The through nozzle (7) is first connected to the guide channel (12) in the conveying direction (A) of the deformable nozzle (1), followed by a cold air supply port (8). The airflow (C) entering the guide channel (12) from the through nozzle (7) is at least partially oriented in the conveying direction (A), and the reverse airflow (D) entering the guide channel (12) from the cold air supply port (8) is at least partially oriented opposite to the conveying direction (A).

4. The method of claim 3, wherein, The reverse airflow (D) has environmental pressure.

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