Production method of self-coloring regenerated bi-component PES yarn capable of adapting to atrocious weather conditions

Abstract

The invention relates to a production method of a self-coloring regenerated bi-component PES (Polyether Sulfonate) yarn suitable for outdoor textile materials.

Description

Technical Field

[0001] The present invention relates to a method for producing a self-coloring regenerated bicomponent polyester (PES) yarn suitable for outdoor textile materials. Background Art

[0002] Outdoor textiles are used in areas requiring high light and outdoor and climatic conditions, such as awnings, tarpaulins, parasols, outdoor curtains, outdoor seating groups, cushions, garden furniture and sunbeds. The fabrics used in these outdoor applications need to be highly resistant to external climate changes such as sunlight, rain, wind, etc., and have high strength.

[0003] In current technology, outdoor textiles mostly use yarns made from acrylic fibers. Due to its structure, acrylic fibers are naturally resistant to the erosion of ultraviolet rays and are therefore often preferred in the production of outdoor textiles. However, due to the high cost of acrylic fibers, their supply is becoming increasingly difficult.

[0004] In addition, with the increase in environmental protection activities, the circular economy, a new production model based on sustainability and innovation, has become increasingly important in recent years, in which every waste generated in the production system is re-evaluated to minimize the cost of raw materials and maximize resource efficiency and environmental benefits. In the existing technology, three different polyester recycling methods can be used: physical / mechanical recycling, semi-physical recycling and chemical recycling. Physical / mechanical recycling is widely used, especially in the recycling of polyethylene terephthalate (PET) bottles. After the collected PET bottles are washed with various detergents, they are crushed and sold in the form of flakes (small fragments). Impurities such as polyethylene are separated due to different densities. Polyvinyl chloride (PVC) impurities are mainly separated physically in large quantities by PVC detectors. The semi-physical recycling method is used to make the product more homogeneous. The PET bottles are melted by extrusion, and the resulting molten PET is then passed through a polymer filter to obtain a cleaner and uniform polymer. Another recycling activity applied today is to use different recycling methods to convert textiles into various semi-finished and finished products for many fields, instead of dealing with clothing waste formed during the production process and regarded as waste.

[0005] Changing economic conditions and environmental factors have prompted manufacturers to develop and produce different UV-resistant fabric structures. Patent application EP2377991B1, one of the studies on this subject, describes at least one UV-resistant additive and a fabric containing natural flame-retardant fibers, which is contained in natural flame-retardant fibers. In the related application, it is pointed out that the flame-retardant fiber contains aromatic polyamide fibers, and at least one UV-resistant additive is incorporated into the fiber through a dyeing process using a carrier.

[0006] The invention of patent application WO2021158196A1 relates to improving the resistance of acrylic fibers containing at least 85% acrylonitrile groups or modified polyacrylonitrile fibers containing at least 40% acrylonitrile groups and at least 40% vinylidene chloride groups produced for outdoor textiles to ultraviolet light and surface heating.

[0007] In the above applications, different methods are used to impart UV protection to fabrics made of different raw materials. In the process steps of the above methods, wastes that are harmful to human and environmental health are present. The methods, labor input, time and chemicals used above cannot reduce costs to the required investment level.

[0008] Therefore, in response to the above-mentioned problems and shortcomings, it is necessary to innovate in relevant technical fields. Summary of the invention

[0009] The present invention relates to a process for producing a self-dyed, regenerated bicomponent PES yarn which meets the above requirements, eliminates all disadvantages and provides some additional advantages.

[0010] The object of the present invention is to provide a method for producing a regenerated bicomponent PES yarn which has a higher UV resistance and does not require recoloring.

[0011] The object of the present invention is to achieve in a single process step the process of obtaining a bicomponent PES yarn from recycled plastic scraps while achieving coloration and improving its UV resistance to a level higher than that of current UV-resistant production technologies.

[0012] The purpose of the present invention is to reduce the use of dyes, reduce the use of chemical additives and improve the UV resistance of self-dyed, regenerated bicomponent PES yarns during production.

[0013] The purpose of the present invention is to shorten the production process, thereby eliminating waste in the production process and ensuring the environmental friendliness of the production process.

[0014] The object of the present invention is to eliminate chemical and dye waste generated in the yarn or fabric dyeing process.

[0015] The object of the present invention is to reduce labor, production time and costs.

[0016] In order to achieve the above-mentioned object, the present invention relates to a method for producing a self-colored regenerated bicomponent PES yarn for outdoor textile materials, the method comprising the following process steps:

[0017] Recycled fragments obtained from waste plastic products,

[0018] Using a horizontal crystallizer with a static ultra-dry air supply, the chips are kept in drying silo A and drying silo B with hot air between 150-165°C until the moisture content of the chips drops below 50 ppm,

[0019] Using an automatic system, the regenerated chips with the required moisture content are fed in equal proportions (1:1) into the extruder filling chamber A heated to 280-300°C and into the extruder filling chamber B heated to 280-295°C,

[0020] To increase the resistance of the yarn to UV rays and to color the yarn, a masterbatch is added to the extruder filling chamber A, and an ultraviolet (UV) additive in the form of a masterbatch is added to the extruder filling chamber B together with a polybutylene terephthalate (PBT) carrier,

[0021] The chips are melted during transport in the extruder filling chamber A and the extruder filling chamber B by means of the screw,

[0022] Pass the molten regenerated PES polymer through a filter at 100-200 bar,

[0023] The regenerated PES polymer is fed into the nozzle at a certain speed by a melt pump and a regular flow rate of 110-210 bar is provided through the holes in the nozzle,

[0024] Cool the melt flowing out of the hole in the nozzle with 60-80% humidity air at 15-30°C sent from the cooling chamber,

[0025] The cooled regenerated bicomponent filament is lubricated with antistatic and anti-static oil through a lubrication wheel,

[0026] Winding the lubricated regenerated bicomponent filaments on a godet roller 1 heated to 80-120°C and a godet roller 2 heated to 100-140°C, respectively, by applying gravity thereto to increase the crystallized area in the structure,

[0027] · drafting the yarn at a ratio of the speed of the godet roller 2 to the speed of the godet roller 1 in the range of 1.5 to 5 times,

[0028] The obtained bicomponent PES yarn is wound around the godet roller 3 and fixed.

[0029] To achieve the purpose of the present invention, 65% of recycled chips and 1%-4% of masterbatch were added to extruder filling chamber A, and 35% of recycled chips and 3%-5% of UV additives in the form of PBT carrier masterbatch were added to extruder filling chamber B.

[0030] To achieve the purpose of the present invention, in the method, heat transfer oil vapor evaporated at 256° C. is used as the protective gas, so that all the pipes through which the melt passes from the extruder filling chamber A and the extruder filling chamber B to the nozzle outlet are at a constant temperature.

[0031] The structures and characteristics of the present invention will be clearly understood through the following detailed description and thus should be evaluated by considering the detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 : General view of the components used to produce the yarn of the present invention.

[0033] The drawings are not necessarily drawn to scale and details that are not necessary for understanding the present invention may be omitted. In addition, components that are at least substantially the same or have at least substantially the same function are denoted by the same numerals.

[0034] Part Reference Number Description

[0035] 1. Drying silo A

[0036] 2. Drying silo B

[0037] 3. Extruder filling chamber A

[0038] 4. Extruder filling chamber B

[0039] 5. Extruder screw

[0040] 6. Filters

[0041] 7. Melt pump

[0042] 8. Nozzle

[0043] 9. Cooling room

[0044] 10. Lubrication wheel

[0045] 11. Godet roller 1

[0046] 12. Godet roller 2

[0047] 13. Godet roller 3 DETAILED DESCRIPTION

[0048] In the present specific embodiment, a method for producing a self-dyed regenerated bicomponent PES yarn adapted to severe weather conditions is described only for a better understanding of the subject matter and in a non-limiting manner.

[0049] The invention relates to a method for producing a self-coloring regenerated bicomponent PES yarn suitable for outdoor textile materials.

[0050] The method for producing regenerated bicomponent PES yarn of the present invention comprises the following process steps:

[0051] Recycled fragments obtained from waste plastic products,

[0052] Using a horizontal crystallizer with a static ultra-dry air supply, the chips are kept in drying silo A (1) and drying silo B (2) with hot air between 150-165°C until the moisture content of the chips drops below 50 ppm,

[0053] Using an automatic system, the regenerated chips with the required moisture content are fed in equal proportions (1:1) into the extruder filling chamber A (3) heated to 280-300°C and into the extruder filling chamber B (4) heated to 280-295°C,

[0054] To increase the resistance of the yarn to UV rays and to color the yarn, a masterbatch is added to the extruder filling chamber A (3), and a UV additive in the form of a masterbatch is added to the extruder filling chamber B (4) together with a PBT carrier,

[0055] The regenerated chips are melted during transportation in the extruder filling chamber A (3) and the extruder filling chamber B (4) by means of the screw,

[0056] Pass the molten regenerated PES polymer through a filter (6) at 100-200 bar,

[0057] The regenerated PES polymer is fed into the nozzle (8) at a certain speed by means of a melt pump (7) and a regular flow rate of 110-210 bar is provided through the holes in the nozzle (8),

[0058] Cooling the melt flowing out of the hole in the nozzle (8) with 60-80% humidity air at 15-30°C sent from the cooling chamber (9),

[0059] The cooled regenerated bicomponent filament is passed through a lubricating wheel (10) and lubricated with antistatic and anti-static oil,

[0060] The lubricated regenerated bicomponent filaments are respectively wound on a godet roller 1 heated to 80-120°C and a godet roller 2 heated to 100-140°C to increase the crystalline area in the structure by applying gravity thereto,

[0061] · drafting the yarn at a ratio of the speed of the godet roller 2 to the speed of the godet roller 1 in the range of 1.5 to 5 times,

[0062] The obtained bicomponent PES yarn is wound around the godet roller 3 (13) and fixed.

[0063] Figure 1 A general view of the components used to produce the yarn of the present invention is shown.

[0064] When the moisture content of the regenerated chips changes, stability problems may occur during production. In order to avoid this disadvantage, in the production method of the present invention, the moisture content of the regenerated chips is controlled to be less than 50ppm.

[0065] In the method of the present invention, heat transfer oil vapor evaporated at 256° C. is used to protect all pipes through which the melt passes from extruder filling chamber A (3) and extruder filling chamber B (4) to the nozzle (8) at a constant temperature.

[0066] In the method of the present invention, the yarn withdrawal is adjusted so that the yarn orientation is carried out with the speed ratio of the godet roller 2 to the godet roller 1 being in the range of 1.5 to 5 times.

[0067] In the method of the present invention, the regenerated bicomponent PES yarn that reaches the highest crystal structure level after being ejected is wound onto a coil through a winding device at a speed of 4000-4600 m / min. By this extraction method, the yarn is made into a FDY (fully drawn yarn) form. All conditions from the crystallizer to the godet roller are used in the same manner with a 2900-3300 m / min fast cooling godet roller and a 2900-3300 m / min winding speed and wound onto the godet roller in the form of POY (partially oriented yarn).

[0068] The obtained yarn was tested and checked for color fastness and strength loss according to ISO 105B04 standard. The grade of the prepared yarn was found to be between 7 and 8 according to the color fastness test. From the result, it can be seen that a high variation in color fastness was observed compared to the existing yarn.

[0069] In preparing self-coloring, recycled bicomponent PES yarn with enhanced UV resistance, 65% recycled chips and 1%-4% masterbatch are added to extruder filling chamber A (3), and 35% recycled chips and 3%-5% UV additive in the form of PBT carrier masterbatch are added to extruder filling chamber B (4).

Claims

1. A method for producing self-colored regenerated bicomponent polyester (PES) yarn that can adapt to adverse weather conditions, characterized in that: The method comprises the following process steps: a. Recycled fragments obtained from waste plastic products, b. Using a horizontal crystallizer with a static ultra-dry air supply, the chips are kept in drying silo A (1) and drying silo B (2) with hot air between 150-165°C until the moisture content of the chips drops below 50 ppm, c. Using an automatic system, the recycled chips with the required moisture content are fed in equal proportions (1:1) into the extruder filling chamber A (3) heated to 280-300°C and into the extruder filling chamber B (4) heated to 280-295°C, d. To improve the resistance of the yarn to UV rays, the yarn is colored, a masterbatch is added to the extruder filling chamber A (3), and a UV additive in the form of a masterbatch is added to the extruder filling chamber B (4) together with a polybutylene terephthalate (PBT) carrier, e. melting the regenerated fragments in the extruder filling chamber A (3) and the extruder filling chamber B (4) by means of a screw during transportation, f. passing the molten regenerated PES polymer through a filter (6) at 100-200 bar, g. The regenerated PES polymer is fed into the nozzle (8) at a certain speed by a melt pump (7), and a regular flow rate of 110-210 bar is provided through the hole in the nozzle (8), h. cooling the melt flowing out of the hole in the nozzle (8) with 60-80% humidity air at 15-30°C sent from the cooling chamber (9), i. The cooled regenerated bicomponent filament is lubricated with antistatic anti-electric oil through a lubrication wheel (10), j. The lubricated regenerated bicomponent filaments are respectively wound on a godet roller 1 (11) heated to 80-120° C. and a godet roller 2 (12) heated to 100-140° C., and gravity is applied thereto to increase the crystalline region in the structure, k. applying drafting to the yarn with a speed ratio of the godet roller 2 to the godet roller 1 in the range of 1.5-5 times, 1. The obtained two-component PES yarn is wound on the godet roller 3 (13) and fixed.

2. The production method according to claim 1, characterized in that The method comprises the following process steps: in process step d, 65% of recycled chips and 1%-4% of masterbatch are added to the extruder filling chamber A (3), and 35% of recycled chips and 3%-5% of UV additives in the form of PBT carrier masterbatch are added to the extruder filling chamber B (4).

3. The production method according to claim 1, characterized in that The method comprises the following process steps: using evaporated heat transfer oil steam at 256°C to protect all pipes through which the melt passes from the extruder filling chamber A (3) and the extruder filling chamber B (4) to the outlet of the nozzle (8) at a constant temperature.

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