Soundproof polyester fdy fiber and preparation method thereof

Abstract

The application belongs to the technical field of sound insulation materials, and relates to a sound insulation polyester FDY fiber and a preparation method thereof. The preparation method comprises a spinning assembly spinning process, a circular blowing air cooling process, a stretching process, a setting process and a main network process. In the spinning assembly, the number of spinning holes on the spinning plate is 96-144, and the spinning holes are divided into two types. Both types of the spinning holes are five-leaf-shaped. The number ratio of the first type of the spinning holes to the second type of the spinning holes is 1-2:1. The diameter of the spinning plate is 95-105 mm. The stretching is completed by the first heat roller, the second heat roller and the third heat roller together, and the temperature of the first heat roller and the second heat roller is 90-94 DEG C. The setting is completed by the third heat roller and the fourth heat roller together. The air pressure of the main network is 0.55-0.6 MPa. The sound insulation effect of the material is significantly improved, and the physical strength and the processing stability of the material are ensured.

Description

Technical Field

[0001] This invention belongs to the field of sound insulation materials technology, and relates to a sound insulation polyester FDY fiber and its preparation method. Background Technology

[0002] With the rapid development of modern industry and technology, the intensification of production activities has inevitably brought about many environmental problems. Among them, noise pollution, as a kind of invisible public hazard, is increasingly becoming a major factor affecting people's quality of life, work efficiency, and physical and mental health. Whether it is the need for a quiet learning environment, the focused atmosphere of the workplace, or the high standards of sound quality pursued in leisure and entertainment spaces such as recording studios, broadcasting studios, cinemas, and concert halls, there is an urgent need to take effective noise control measures.

[0003] In traditional noise control methods, sound-absorbing and sound-insulating materials play a crucial role. Currently, most mainstream sound-absorbing and noise-reducing materials on the market are made of fine-denier, porous polyester fibers. These materials, through their unique microstructure—a large number of interconnected tiny pores—can effectively capture and dissipate incident noise waves. When sound waves act on the material surface, they excite the vibration of air molecules within the fibers and their pores. This vibration, combined with friction, viscous resistance, and the material's thermal conductivity, converts sound energy into heat energy, significantly reducing the intensity of sound reflection and achieving sound insulation and noise reduction.

[0004] However, while pursuing high-efficiency sound insulation performance, existing technologies also face some insurmountable challenges. For example, a porous sound insulation material disclosed in patent application CN108017360A effectively increases the porosity between fibers by adding inorganic additives such as gypsum and ceramsite to polyester fibers, thereby improving the sound insulation effect. However, this approach comes at the cost of sacrificing the physical strength of the material. Excessive additives lead to a decrease in the overall mechanical properties of the fibers, affecting the durability and application range of the material.

[0005] The literature (Research on the structure and sound absorption properties of composite needle-punched nonwoven fabrics [J]. Nonwoven Fabrics, 2009(4): 31-34) also points out that the fineness of the fiber has a direct impact on the sound absorption and sound insulation performance of the material. The finer the fiber, the higher the sound absorption and sound insulation coefficient of the material. However, excessive fiber fineness will lead to a significant decrease in fiber strength, which not only weakens the weaving and processing performance of the material, but also shortens its service life, thus limiting the promotion of such high-performance materials in practical applications.

[0006] In summary, the urgent technical challenge in the field of sound-absorbing and sound-insulating materials is how to further improve their sound insulation effect without sacrificing the material's physical strength and processing performance, and to develop new sound-absorbing and sound-insulating materials that are both efficient and durable to meet the growing demand for noise control. Summary of the Invention

[0007] The purpose of this invention is to solve the problems existing in the prior art and to provide a sound-insulating polyester FDY fiber and its preparation method.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0009] A method for preparing sound-insulating polyester FDY fiber includes a spinning assembly spinning process, a ring blowing cooling process, a stretching process, a setting process, and a main network process. In the spinning assembly, the number of spinneret holes on the spinneret is 96-144, which are divided into two categories.

[0010] Both types of spinnerets are five-lobed, consisting of a circle and five long blades that are connected to the circle and distributed radially. The diameter of the circle is 0.23±0.01mm, and the included angle between two adjacent blades is 72°.

[0011] The first type of spinneret has a blade length of 0.4 mm and a blade width of 0.055 mm; the second type of spinneret has a blade length of 0.4 mm and a blade width of 0.03 mm.

[0012] The ratio of the number of type I spinnerets to the number of type II spinnerets is 1-2:1;

[0013] The diameter of the spinneret is 95-105mm;

[0014] The stretching is accomplished by the first hot roller, the second hot roller and the third hot roller together, with the temperature of the first hot roller and the second hot roller being 90-94℃;

[0015] The shaping process is completed jointly by the third and fourth hot rollers.

[0016] The air pressure in the main network is 0.55-0.6 MPa.

[0017] This invention designs the dimensions of two types of spinnerets so that the filaments extruded from the first type of spinneret have relatively large fineness and relatively small radial anisotropy, denoted as filament A; the filaments extruded from the second type of spinneret have relatively small fineness and relatively large radial anisotropy, denoted as filament B.

[0018] Controlling the temperature of the first and second hot rollers, as well as the air pressure of the main network, can result in the surface of the sound-insulating polyester FDY fiber (a multifilament composed of multiple monofilaments A and B) having a fuzzy texture, for the following reasons:

[0019] When monofilaments A and B pass through the first and second hot rollers, due to the high temperature of the first and second hot rollers, they are prone to crystallization and shaping. When they are stretched and shaped later, monofilament B, which has a relatively small fineness and a relatively large radial anisotropy, is more likely to develop fuzz, while monofilament A, which has a relatively large fineness and a relatively small radial anisotropy, is less likely to develop fuzz.

[0020] During the main network construction, monofilament B, which has a relatively small fineness and relatively large radial anisotropy, is more prone to breakage than monofilament A, which has a relatively large fineness and relatively small radial anisotropy. By controlling the air pressure of the main network, monofilament B can be broken and simultaneously intertwined with monofilament A, forming dense and uniform filaments on the surface of the sound-insulating polyester FDY fiber. Monofilament A does not break, thus ensuring the strength of the sound-insulating polyester FDY fiber.

[0021] When the diameter of the spinneret is large (95-105mm), the heat dissipation speed of the plate surface is fast, the plate surface temperature is relatively low, which is equivalent to a fast cooling speed and a relatively higher radial anisotropy. When passing through the main network, the monofilament B is more likely to produce fuzz.

[0022] Controlling the ratio of the number of first-type spinnerets to the number of second-type spinnerets can ensure high strength and stable post-processing performance of sound-insulating polyester FDY fibers.

[0023] Fabrics containing this sound-insulating polyester FDY fiber have good sound insulation properties, mainly for the following reasons:

[0024] ① The monofilament cross-section of the sound-insulating polyester FDY fiber is pentagonal. The pentagonal shape has many edges and corners. When sound travels into the fabric, it will cause the fibers and the air between the fibers to vibrate. Due to this vibration, more friction will be generated between the air and the fibers, which will reduce the sound.

[0025] ② The monofilament cross-section of the sound-insulating polyester FDY fiber is pentagonal. The pentagonal shape has a relatively large number of blades, and when sound propagates to the surface of the fiber, it will produce more diffuse reflection (after one incident and multiple reflections). Since the sound waves of different reflections are prone to misalignment, they can weaken or even cancel each other out. At the same time, multiple reflections are equivalent to increasing the sound propagation path, thereby weakening the sound.

[0026] ③ The sound-insulating polyester FDY fiber has a large number of monofilaments (96-144), and the cross-section of the monofilament is five-lobed and small in size, which makes the specific surface area of ​​the sound-insulating polyester FDY fiber larger. When sound propagates, the sound waves interact more strongly with the fiber, thus reducing the sound more effectively.

[0027] ④ The surface of the sound-insulating polyester FDY fiber is covered with fuzzy fibers. These fuzzy fibers, in a curved, feathery shape, easily resonate with sound waves, absorb energy, and weaken the sound wave intensity. At the same time, they make the fabric more fluffy, which is equivalent to increasing the fabric density and thickness, and also increases the sound propagation path, thus improving the sound insulation and absorption effect.

[0028] As a preferred technical solution:

[0029] In the above-described method for preparing sound-insulating polyester FDY fiber, all the spinnerets are arranged in concentric circles on the spinneret. The first type of spinnerets is arranged on the outer ring of the spinneret, and the second type of spinnerets is arranged on the inner ring of the spinneret. With this design, under the same cooling air pressure conditions, monofilament B can be cooled uniformly, while monofilament A will experience slight insufficient cooling, resulting in higher elongation at break and boiling water shrinkage.

[0030] In the above-described method for preparing sound-insulating polyester FDY fiber, the filter sand used in the spinning assembly is 150-180g (total mass of metal sand) of 50-70 mesh metal sand.

[0031] The metal sand selected in this invention has a suitable mesh size, which can ensure filtration accuracy and avoid the instantaneous rise in melt temperature caused by high pressure of the spinning assembly, thus affecting the relative radial anisotropy of the fibers.

[0032] The method for preparing sound-insulating polyester FDY fiber as described above involves a spinning temperature of 286-290℃.

[0033] The spinning temperature of this invention is relatively low, which can increase the relative radial anisotropy of the fiber on the one hand, and increase the swelling effect of the polyester melt at the spinneret on the other hand. This results in the monofilament B having a smaller residual elongation and a relatively lower breaking strength after stretching during the spinning process, making it easier to produce uniform filaments when subjected to high pressure impact from the main network.

[0034] In the above-described method for preparing sound-insulating polyester FDY fiber, the cooling air pressure of the ring-blowing cooling is 35-40 Pa, the length of the cooling duct is 48-50 cm, and the height of the slow cooling zone is 55-60 mm.

[0035] The specific cooling air pressure, cooling duct length, and slow cooling zone height ensure that monofilament B is cooled properly, while monofilament A is not cooled properly, resulting in a larger breaking elongation and boiling water shrinkage rate. After subsequent weaving, monofilament A with a high boiling water shrinkage rate appears as small loops floating on the fabric surface, creating a fluffy effect. This makes the end face of the fabric feel denser, thereby improving the sound insulation performance.

[0036] In the above-described method for preparing sound-insulating polyester FDY fiber, the rotational speed ratio (i.e., stretching ratio) of the third hot roller to the first hot roller is 2.0-2.5.

[0037] Monofilament B is prone to producing low-strength, low-elongation monofilaments due to large stretching ratios during the stretching process, and is more likely to develop fuzz after being blown by high pressure through the main network.

[0038] The preparation method of sound-insulating polyester FDY fiber as described above has the following overall process flow: melt extrusion via metering pump → spinning via spinning assembly → cooling via ring blowing → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main networking → third guide roller → winding and forming.

[0039] In the above-described method for preparing sound-insulating polyester FDY fiber, the first pre-network is located 130-140 cm below the spinneret, the air pressure of the first pre-network is 0.03-0.04 MPa, and the air pressure of the second pre-network is 0.1-0.15 MPa.

[0040] Pre-networking the fiber bundle improves fiber cohesion and binding, allowing the fibers to bind together effectively after passing through the main network and preventing them from falling out of the bundle. Because the fiber bundle speed is high and the tension is relatively large at the second pre-networking stage, the air pressure in the second pre-networking stage is slightly higher.

[0041] The present invention also provides a sound-insulating polyester FDY fiber prepared by the method described in any one of the preceding claims, wherein the surface is distributed with filaments, the length of which is 0.5-1.0 cm and the filaments are curved with a bending radius of 2-4 cm; the sound-insulating polyester FDY fiber has a breaking strength ≥3.84 cN / dtex, a breaking elongation of 28.8-32.7%, a differential shrinkage rate of 12.4-18.2%, a relative radial anisotropy ≥24.7% (a high relative radial anisotropy indicates that the leaf length of the five-leaf structure is longer and the sound absorption effect is better), an oil content of 0.39-0.45%, and a filament content ≥91.5%.

[0042] This invention also provides a method for preparing sound-insulating polyester composite fiber, wherein polyester POY fiber and sound-insulating polyester FDY fiber are passed in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, the polyester POY fiber is passed through a false twister and twisted with the sound-insulating polyester FDY fiber at the second roller. Finally, the fiber is passed through a network, an auxiliary roller, a second hot box, a third roller, oiled, and wound to form the sound-insulating polyester composite fiber.

[0043] The sound-insulating polyester FDY fiber is the sound-insulating polyester FDY fiber as described above;

[0044] The temperature of the first heating chamber is 150-160℃.

[0045] Because sound-insulating polyester FDY fibers have a five-lobed cross-section, their tensile strength is relatively low, and the surface of the filament bundle is covered with fuzz, which easily accumulates during the subsequent weaving process. If too much fuzz accumulates in the comb, the fibers are prone to breakage. Furthermore, if sound-insulating polyester FDY fibers are directly woven into the final product, the fuzz effect will not exhibit a good bending state due to the lack of further high-temperature heating to plasticize the filament bundle, resulting in relatively poor sound insulation. Therefore, this invention combines sound-insulating polyester FDY fibers with polyester POY fibers to obtain sound-insulating polyester composite fibers, which are then used as the fiber raw material for weaving fabrics.

[0046] There are two main processes for producing composite fibers using existing technologies:

[0047] ① FDY fibers are networked together with POY fibers that have passed through a pre-network, first roller, first hot box, cooling plate, false twister, and second roller in sequence, and then passed through an auxiliary roller, second hot box, third roller, oiling, and winding to obtain heterogeneous shrinkage fibers;

[0048] ② The POY fiber and FDY fiber are pre-networked together, and then passed through the first roller, the first hot box, the cooling plate, the false twister, the second roller, the second hot box, the third roller, oiling, and winding to obtain the imitation cotton fiber.

[0049] The process for producing composite fibers in this invention differs from existing technologies. Firstly, the FDY fibers of this invention undergo a first heating chamber before being combined with POY fibers. This process improves the fluffiness and fullness of the FDY fibers. The temperature of the first heating chamber must be appropriate; if the temperature is too high, the fibers of the sound-insulating polyester FDY fibers are prone to breakage; if the temperature is too low, the polyester POY fibers are not sufficiently softened, and the fibers are prone to breakage when passing through the false twister. Secondly, the FDY fibers of this invention do not pass through the false twister because they have a large number of fibers, which are prone to breakage if passed through the false twister.

[0050] As a preferred technical solution:

[0051] In the above-described method for preparing sound-insulating polyester composite fiber, the speed of the second roller is 600-620 m / min. The relatively low speed of the second roller is mainly to ensure stable production and the velvety texture of the product, so that the two bundles of fibers have good cohesion.

[0052] The method for preparing sound-insulating polyester composite fiber as described above has a speed ratio of 1.65-1.68 between the second roller and the first roller, and a speed ratio of 1.60-1.65 between the surface linear velocity of the friction disc of the false twister and the speed of the second roller. This method is mainly used for false twisting deformation of polyester POY fibers.

[0053] In the above-described method for preparing sound-insulating polyester composite fiber, the temperature of the second heating box is 175-185℃, and its main function is to set the shape.

[0054] The present invention also provides a sound-insulating polyester composite fiber prepared by the method described in any one of the preceding claims, wherein the sound-insulating polyester composite fiber has a breaking strength ≥3.25cN / dtex, a breaking elongation of 14.1-15.9%, an oil content of 2.8-3.2%, a crimp shrinkage of 14.3-15.7% (ensuring the fluffiness of the fiber crimp), a crimp stability ≥78.6%, and a fuzz rate ≥91.6%; and the sound absorption coefficient a of the fabric made from the sound-insulating polyester composite fiber is ≥0.22.

[0055] Beneficial effects:

[0056] (1) This invention designs two types of spinnerets with different sizes and irregularities to produce sound-insulating polyester FDY fibers composed of monofilament A with larger fineness and smaller irregularity and monofilament B with smaller fineness and larger irregularity. This design enables dense and uniform filaments to be formed on the fiber surface, increases the specific surface area of ​​the fiber, enhances the interaction with sound waves, and thus significantly improves the sound insulation performance.

[0057] (2) By precisely controlling parameters such as the air pressure of the first hot roller, the second hot roller and the main network, the present invention makes it easy for monofilament B to break during the stretching process and to intertwine with monofilament A to form an ideal fuzzy effect, while ensuring the integrity of monofilament A, thereby improving the sound insulation performance without sacrificing fiber strength.

[0058] (3) Sound-insulating polyester FDY fiber is compounded with polyester POY fiber to obtain sound-insulating polyester composite fiber. This step not only further enhances the sound insulation performance of the fiber, but also improves the fluffiness of the sound-insulating polyester FDY fiber and makes the feel fuller through the preparation process of composite fiber. At the same time, the sound-insulating polyester FDY fiber and its composite fiber are not easy to break during the subsequent weaving process, and are easy to process into sound insulation materials of various shapes and sizes, which meet the noise control needs of different occasions. Attached Figure Description

[0059] Figure 1 This is a schematic diagram showing the distribution of spinneret holes on the spinneret used in Example 1;

[0060] Figure 2 for Figure 1 Schematic diagram of the shapes of the two types of spinnerets;

[0061] Figure 3 This is a schematic diagram showing the shapes of the two types of spinnerets in Comparative Example 3;

[0062] Figure 4This is a schematic diagram showing the distribution of spinneret holes on the spinneret used in Example 5;

[0063] Where A represents the first type of spinneret, B represents the second type of spinneret, d1 represents the blade length, d2 represents the blade width, and d3 represents the diameter of the circle that makes up the five-leaf shape. Detailed Implementation

[0064] The present invention will be further described below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0065] The following are the test methods for the relevant performance indicators in each embodiment and comparative example:

[0066] Whether it has fuzz: By visual inspection, the presence of broken single filaments on the surface of each filament roll indicates fuzz.

[0067] The length of the hair: observed visually and measured with a ruler.

[0068] The radius of the hair bending: observed visually and measured with a ruler.

[0069] Breaking strength and elongation at break: According to the standard "Test Method for Tensile Properties of Chemical Fiber Filaments" (GB / T 14344-2022), the elongation at break of the filament bundle was tested using a YG023B-Ⅱ fully automatic single yarn tensile testing machine. The specific process was as follows: First, the filament bundle was conditioned for 4 hours in an environment with a temperature of (20±2)℃ and a humidity of (65±5)%. Then, a tensile test was performed using the fully automatic single yarn tensile testing machine. Before the test, the clamping length of the filament bundle was precisely set to (500±1.0) mm by the upper and lower clamps, and a pretension of (0.05±0.005 cN / dtex) was applied by the robot arm to stabilize the filament bundle. During the test, the lower clamp was stretched uniformly at a set speed (500 mm / min) until the filament bundle broke. During the stretching process, the force sensor recorded the data in real time, and the relationship curve between strength and elongation was plotted by the data collection system. Finally, the breaking strength and elongation at break of the filament bundle were obtained through data processing and analysis.

[0070] Differential shrinkage rate: The test was conducted in accordance with the standard "Test method for differential shrinkage rate of polyester pre-oriented yarn, drawn yarn and blended yarn" (FZ / T 50023-2014).

[0071] Relative radial anisotropy: According to the "Test Method for Anisotropy of Chemical Fibers" (FZ / T 50002-2013), the cross-section of the fiber is magnified by a microscope, and the radii of the inscribed circle and circumscribed circle in the fiber cross-section are calculated. The relative radial anisotropy D is then calculated using the following formula. R :

[0072] D R = (1-r / R)×100%;

[0073] In the formula, r is the radius of the inscribed circle in the fiber cross section (mm), and R is the radius of the circumscribed circle in the fiber cross section (mm).

[0074] Oil content: According to the standard "Test Method for Oil Content of Chemical Fibers" (GB / T 6504-2017), about 2g of sample was weighed and tested using an MQC23-10 nuclear magnetic resonance oil content analyzer.

[0075] Fiber rate: Fiber rate = Total number of fibers × 100% / Total number of fibers.

[0076] Curl shrinkage rate and curl stability: According to the standard "Test Method for Curl Shrinkage Performance of Synthetic Fiber Textured Yarn" (GB / T 6506-2017), the YG368 fully automatic filament curl shrinkage rate tester was used for testing.

[0077] Sound absorption coefficient a: The sample to be tested is first woven into a fabric by a circular knitting machine, and then tested according to GB / T 18696.1 "Measurement of sound absorption coefficient and acoustic impedance in acoustic impedance tubes - Part 1: Standing wave ratio method".

[0078] Example 1

[0079] A method for preparing sound-insulating polyester FDY fiber, the overall process flow is as follows: melt is extruded by metering pump → spinning by spinning assembly → cooling by ring blowing air → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main networking → third guide roller → winding and forming.

[0080] The melt preparation process is as follows: slurry preparation → first esterification → second esterification → prepolymerization → final polymerization → polyester melt (intrinsic viscosity 0.620 dL / g); the relevant process parameters are: slurry level 69%, PTA mass in slurry accounts for 69% of the total mass of PTA and EG; first esterification temperature 268℃, first esterification pressure 90kPa, second esterification temperature 270℃, second esterification pressure 30kPa, prepolymerization upper chamber temperature 278℃, prepolymerization upper chamber pressure 35kPa, prepolymerization lower chamber temperature 280℃, prepolymerization lower chamber pressure 1.8kPa, final polymerization inlet temperature 280℃, final polymerization outlet temperature 286℃, final polymerization vacuum degree 160Pa;

[0081] In the spinning assembly, the spinneret has a diameter of 105 mm; the spinneret orifices on the spinneret are divided into two types, both of which are five-lobed, such as... Figure 2 As shown, the five-lobed shape consists of a circle and five long lobes that are connected to the circle and arranged radially. The diameter of the circle is 0.23 mm, and the angle between adjacent lobes in the five-lobed shape is 72°. The first type of spinneret has a lobe length of 0.4 mm and a lobe width of 0.055 mm; the second type of spinneret has a lobe length of 0.4 mm and a lobe width of 0.03 mm. Figure 1 As shown, all the spinnerets are concentrically distributed on the spinneret plate, forming a total of 6 circles. The spinnerets on each circle are evenly distributed. The first circle appearing from the inside out is designated as the first circle, with a diameter of 20 mm and 8 second-class spinnerets distributed on it. The second circle has a diameter of 33 mm and 14 second-class spinnerets distributed on it. The third circle has a diameter of 46 mm and 22 second-class spinnerets distributed on it. The fourth circle has a diameter of 59 mm and 28 second-class spinnerets distributed on it. The fifth circle has a diameter of 72 mm and 36 first-class spinnerets distributed on it. The sixth circle has a diameter of 86 mm and 36 first-class spinnerets distributed on it.

[0082] In the spinning assembly, the filter sand is 180g, 50-70 mesh metal sand; the spinning temperature is 286℃.

[0083] The cooling air pressure of the ring-blown cooling system is 40Pa, the length of the cooling air duct is 50cm, and the height of the slow cooling zone is 60mm.

[0084] The first pre-network was located 130cm below the spinneret, and the air pressure for the first pre-network was 0.04MPa.

[0085] The temperature of the first hot roller is 90℃;

[0086] The temperature of the second hot roller is 90℃;

[0087] The speed ratio of the third hot roller to the first hot roller is 2.1;

[0088] The air pressure in the second pre-network was 0.15 MPa;

[0089] The air pressure of the main network is 0.55 MPa.

[0090] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 0.5 cm, and the fibers are curved with a radius of 2 cm. The sound-insulating polyester FDY fiber has a breaking strength of 3.87 cN / dtex, a breaking elongation of 31.6%, an anisotropic shrinkage rate of 18.2%, a relative radial anisotropy of 30.4%, an oil content of 0.45%, and a fuzzy fiber content of 96.7%.

[0091] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 82dtex / 48f, physical properties: breaking strength 2.64cN / dtex, breaking elongation 131.8%, evenness CV value 1.03%, oil content 0.34%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0092] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 160℃; the speed of the second roller is 600m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.65, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.6; and the temperature of the second heating chamber is 185℃.

[0093] The final sound-insulating polyester composite fiber has a breaking strength of 3.25 cN / dtex, a breaking elongation of 14.7%, an oil content of 3.2%, a crimp shrinkage of 15.7%, a crimp stability of 80.8%, and a fuzz rate of 96.8%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.54.

[0094] Comparative Example 1

[0095] A method for preparing polyester FDY fiber differs from Example 1 only in that: the centers of all spinnerets are concentrically distributed on the spinneret plate, totaling 6 circles. The spinnerets on each circle are evenly distributed. The first circle appearing from the inside out is designated as the first circle, with a diameter of 20 mm and 4 second-type spinnerets distributed on it. The second circle has a diameter of 33 mm and 7 second-type spinnerets distributed on it. The third circle has a diameter of 46 mm and 11 second-type spinnerets distributed on it. The fourth circle has a diameter of 59 mm and 14 second-type spinnerets distributed on it. The fifth circle has a diameter of 72 mm and 18 first-type spinnerets distributed on it. The sixth circle has a diameter of 86 mm and 18 first-type spinnerets distributed on it.

[0096] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0097] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.18.

[0098] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber was significantly reduced. This is because in Comparative Example 1, the number of spinneret holes on the spinneret was too low, which means that the number of polyester FDY fiber monofilaments was too small, and thus its specific surface area was relatively small. When sound propagates, the interaction between the sound wave and the fiber is not strong enough, and the sound cannot be effectively reduced, which is reflected in the significant reduction of the sound absorption coefficient α of the fabric.

[0099] Comparative Example 2

[0100] A method for preparing polyester FDY fiber differs from Example 1 only in that both types of spinnerets are four-lobed, with an included angle of 90° between adjacent lobes.

[0101] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0102] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.14.

[0103] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 2 is significantly reduced. This is because both types of spinnerets used in Comparative Example 2 are four-leaf shaped. The four-leaf shape has fewer edges and corners. When sound propagates into the fabric, it causes a weaker degree of vibration in the fibers and the air between the fibers, which cannot effectively reduce the sound, resulting in a significant reduction in the sound absorption coefficient α of the fabric.

[0104] Comparative Example 3

[0105] A method for preparing polyester FDY fiber differs from Example 1 only in that the angles at which the five blades of both types of five-bladed spinnerets are formed are as follows: Figure 3 As shown.

[0106] Compared with Example 1, the relative radial anisotropy of the polyester FDY fiber was significantly reduced. This is because the five blades of the two types of five-bladed spinnerets in Comparative Example 3 were formed at different angles. The blades with smaller included angles were affected by the expansion of the melt after it was extruded from the spinneret, resulting in a lower relative radial anisotropy.

[0107] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0108] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0109] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber was significantly reduced. This is because the two types of five-lobed spinnerets used in Comparative Example 3 formed the five lobes at different angles. The lobes with smaller included angles were affected by the expansion of the melt after it was extruded from the spinneret, resulting in a lower relative radial anisotropy of the polyester FDY fiber. That is, the cross-section of the fiber tended to be more circular, and the sharp edges on the fiber surface were reduced accordingly, which affected the sound absorption effect.

[0110] Comparative Example 4

[0111] A method for preparing polyester FDY fiber differs from Example 1 only in that: the centers of all spinnerets are concentrically distributed on the spinneret plate, totaling 6 circles. The spinnerets on each circle are evenly distributed. The first circle appearing from the inside out is designated as the first circle, with a diameter of 20 mm and 8 second-type spinnerets distributed on it. The second circle has a diameter of 33 mm and 14 second-type spinnerets distributed on it. The third circle has a diameter of 46 mm and 22 second-type spinnerets distributed on it. The fourth circle has a diameter of 59 mm and 28 second-type spinnerets distributed on it. The fifth circle has a diameter of 72 mm and 36 second-type spinnerets distributed on it. The sixth circle has a diameter of 86 mm and 36 first-type spinnerets distributed on it.

[0112] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0113] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0114] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 4 was significantly reduced. This is because in Comparative Example 4, the number of second type spinnerets was too high, that is, the proportion of monofilament B was too high. Monofilament B has a relatively small fineness, a relatively large radial anisotropy, and weak strength, which affects the strength of polyester FDY fiber. As a result, when it is subsequently compounded with polyester POY fiber, monofilament breakage is likely to occur. This leads to poor structural stability of the composite fiber and affects the sound absorption effect.

[0115] Comparative Example 5

[0116] A method for preparing polyester FDY fiber differs from Example 1 only in that the temperature of both the first and second hot rollers is 85°C.

[0117] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0118] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.17.

[0119] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 5 was significantly reduced. This is because the temperature of the first and second hot rollers in Comparative Example 5 was too low, resulting in insufficient crystallization and shaping of monofilament A and monofilament B, which affected the stability of the internal structure of the fiber. Monofilament B was less likely to develop fuzz, thus affecting the sound absorption effect.

[0120] Comparative Example 6

[0121] A method for preparing polyester FDY fiber differs from Example 1 only in that the air pressure of the main network is 0.5 MPa.

[0122] A method for preparing polyester composite fiber differs from Example 1 only in that the sound-insulating polyester FDY fiber prepared in Example 1 is replaced with the polyester FDY fiber prepared in this comparative example.

[0123] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0124] Compared with Example 1, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 6 is significantly reduced. This is because the air pressure of the main network in Comparative Example 6 is too low, making it difficult for the monofilament B, which has a relatively small fineness and relatively large radial anisotropy, to break completely and intertwine with the monofilament A. As a result, dense and uniform filaments cannot be formed on the surface of the polyester FDY fiber, which leads to a weakening of its resonance with sound waves and energy absorption effect, thus reducing the sound absorption coefficient α of the fabric.

[0125] Example 2

[0126] A method for preparing sound-insulating polyester FDY fiber, the overall process flow is as follows: melt is extruded by metering pump → spinning by spinning assembly → cooling by ring blowing air → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main networking → third guide roller → winding and forming.

[0127] The melt preparation process is as follows: slurry preparation → first esterification → second esterification → prepolymerization → final polymerization → polyester melt (intrinsic viscosity 0.630 dL / g); the relevant process parameters are: slurry level 70%, PTA mass in slurry accounts for 69.5% of the total mass of PTA and EG; first esterification temperature 270℃, first esterification pressure 105kPa, second esterification temperature 278℃, second esterification pressure 40kPa, prepolymerization upper chamber temperature 282℃, prepolymerization upper chamber pressure 38kPa, prepolymerization lower chamber temperature 285℃, prepolymerization lower chamber pressure 1.9kPa, final polymerization inlet temperature 282℃, final polymerization outlet temperature 288℃, final polymerization vacuum degree 250Pa;

[0128] In the spinning assembly, the spinneret has a diameter of 95 mm. The spinnerets on the spinneret are divided into two types, both of which are five-lobed. Each five-lobed spinneret consists of a circle and five long blades radially distributed and connected to the circle. The circle has a diameter of 0.22 mm, and the angle between adjacent blades in the five-lobed spinneret is 72°. The blades of the first type of spinneret are 0.4 mm long and 0.055 mm wide; the blades of the second type of spinneret are 0.4 mm long and 0.03 mm wide. The center of all spinnerets is located on the spinneret. The spinnerets are arranged in concentric circles, with a total of 4 circles. The spinnerets on each circle are evenly distributed. The first circle that appears from the inside out is called the first circle. The diameter of the first circle is 36 mm, and it has 14 second-class spinnerets. The diameter of the second circle is 49 mm, and it has 20 second-class spinnerets. The diameter of the third circle is 62 mm, and it has 28 first-class spinnerets. The diameter of the fourth circle is 75 mm, and it has 34 first-class spinnerets.

[0129] In the spinning assembly, the filter sand is 180g, 50-70 mesh metal sand; the spinning temperature is 287℃.

[0130] The cooling air pressure of the ring-blown cooling system is 38Pa, the length of the cooling air duct is 49cm, and the height of the slow cooling zone is 58mm.

[0131] The first pre-network was located 132 cm below the spinneret, and the air pressure of the first pre-network was 0.04 MPa.

[0132] The temperature of the first hot roller is 94℃;

[0133] The temperature of the second hot roller is 94℃;

[0134] The speed ratio of the third hot roller to the first hot roller is 2.3;

[0135] The air pressure in the second pre-network was 0.14 MPa;

[0136] The air pressure in the main network is 0.6 MPa.

[0137] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 0.8 cm, and the fibers are curved with a radius of 2.5 cm. The sound-insulating polyester FDY fiber has a breaking strength of 3.92 cN / dtex, a breaking elongation of 30.4%, an anisotropic shrinkage rate of 16.7%, a relative radial anisotropy of 32.6%, an oil content of 0.43%, and a fuzzy fiber content of 95.4%.

[0138] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 82dtex / 48f, physical properties: breaking strength 2.64cN / dtex, breaking elongation 131.8%, evenness CV value 1.03%, oil content 0.34%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0139] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 150℃; the speed of the second roller is 600m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.68, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.63; and the temperature of the second heating chamber is 185℃.

[0140] The final sound-insulating polyester composite fiber has a breaking strength of 3.39 cN / dtex, a breaking elongation of 14.1%, an oil content of 3%, a crimp shrinkage of 14.9%, a crimp stability of 79.3%, and a fuzz rate of 96.1%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.4.

[0141] Comparative Example 7

[0142] A method for preparing polyester FDY fiber differs from Example 2 only in that: the centers of all spinnerets are concentrically distributed on the spinneret plate, with a total of 4 circles. The spinnerets on each circle are evenly distributed. The first circle appearing from the inside out is designated as the first circle, with a diameter of 36 mm and 14 second-type spinnerets distributed on it. The second circle has a diameter of 49 mm and 20 first-type spinnerets distributed on it. The third circle has a diameter of 62 mm and 28 first-type spinnerets distributed on it. The fourth circle has a diameter of 75 mm and 34 first-type spinnerets distributed on it.

[0143] A method for preparing polyester composite fiber differs from Example 2 only in that the sound-insulating polyester FDY fiber prepared in Example 2 is replaced with the polyester FDY fiber prepared in this comparative example.

[0144] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.08.

[0145] Compared with Example 2, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 7 was significantly reduced. This is because the number of second type spinnerets in Comparative Example 7 was too small, that is, the proportion of monofilament B was too low, which could not form enough filaments, resulting in poor sound absorption of the fabric.

[0146] Comparative Example 8

[0147] A method for preparing polyester FDY fiber differs from Example 2 only in that the air pressure of the main network is 0.65 MPa.

[0148] Compared with Comparative Example 8 and Example 2, the breaking strength of polyester FDY fiber decreased significantly. This is because the main network air pressure is higher, which makes it easier to blow off the entire bundle of monofilament B, resulting in a decrease in breaking strength.

[0149] A method for preparing polyester composite fiber differs from Example 2 only in that the sound-insulating polyester FDY fiber prepared in Example 2 is replaced with the polyester FDY fiber prepared in this comparative example.

[0150] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0151] Compared with Example 2, the sound absorption coefficient α of the fabric made of polyester composite fiber was significantly reduced. This is because the air pressure of the main network in Comparative Example 8 was too high, and the monofilament B was excessively broken, which affected the strength of the polyester FDY fiber. As a result, when it was subsequently compounded with polyester POY fiber, monofilament breakage was likely to occur, which would lead to poor structural stability of the composite fiber and affect the sound absorption effect.

[0152] Comparative Example 9

[0153] The only difference between this method for preparing polyester composite fiber and Example 2 is that the temperature of the first hot box is 145°C.

[0154] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.18.

[0155] Compared with Example 2, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 9 was significantly reduced. This is because the temperature of the first heating box in Comparative Example 9 was too low, and the polyester POY fiber was not softened enough. When it passed through the false twister, the fibers were more likely to break, which affected the sound absorption effect of the fabric.

[0156] Example 3

[0157] A method for preparing sound-insulating polyester FDY fiber, the overall process flow is as follows: melt is extruded by metering pump → spinning by spinning assembly → cooling by ring blowing air → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main networking → third guide roller → winding and forming.

[0158] The melt preparation process is as follows: slurry preparation → first esterification → second esterification → prepolymerization → final polymerization → polyester melt (intrinsic viscosity 0.625 dL / g); the relevant process parameters are: slurry level 69%, PTA mass in slurry accounts for 70% of the total mass of PTA and EG; first esterification temperature 269℃, first esterification pressure 100kPa, second esterification temperature 275℃, second esterification pressure 35kPa, prepolymerization upper chamber temperature 280℃, prepolymerization upper chamber pressure 36kPa, prepolymerization lower chamber temperature 283℃, prepolymerization lower chamber pressure 2kPa, final polymerization inlet temperature 281℃, final polymerization outlet temperature 287℃, final polymerization vacuum degree 200Pa;

[0159] In the spinning assembly, the spinneret has a diameter of 96 mm. The spinnerets on the spinneret are divided into two types, both of which are five-lobed. Each five-lobed spinneret consists of a circle and five long blades radially distributed and connected to the circle. The circle has a diameter of 0.24 mm, and the angle between adjacent blades in the five-lobed spinneret is 72°. The blades of the first type of spinneret are 0.4 mm long and 0.055 mm wide; the blades of the second type of spinneret are 0.4 mm long and 0.03 mm wide. The center of all spinnerets is located on the spinneret. The spinnerets are arranged in concentric circles, with a total of 4 circles. The spinnerets on each circle are evenly distributed. The first circle that appears from the inside out is called the first circle. The diameter of the first circle is 36 mm. The first circle has 14 second-class spinnerets. The diameter of the second circle is 50 mm. The second circle has 18 second-class spinnerets. The diameter of the third circle is 63 mm. The third circle has 30 first-class spinnerets. The diameter of the fourth circle is 76 mm. The fourth circle has 34 first-class spinnerets.

[0160] In the spinning assembly, the filter sand is 160g, 50-70 mesh metal sand; the spinning temperature is 289℃.

[0161] The cooling air pressure of the ring-blown cooling system is 35Pa, the length of the cooling air duct is 48cm, and the height of the slow cooling zone is 55mm.

[0162] The first pre-network was located 138 cm below the spinneret, and the air pressure of the first pre-network was 0.03 MPa.

[0163] The temperature of the first hot roller is 92℃;

[0164] The temperature of the second hot roller is 92℃;

[0165] The speed ratio of the third hot roller to the first hot roller is 2.5;

[0166] The air pressure in the second pre-network was 0.13 MPa;

[0167] The air pressure of the main network is 0.55 MPa.

[0168] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 0.9 cm, and the fibers are curved with a radius of 3.5 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.14 cN / dtex, a breaking elongation of 28.8%, an anisotropic shrinkage rate of 15.4%, a relative radial anisotropy of 35.4%, an oil content of 0.42%, and a fuzzy fiber content of 95.1%.

[0169] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 80dtex / 72f, physical properties: breaking strength 2.54cN / dtex, breaking elongation 130.2%, evenness CV value 1.12%, oil content 0.33%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0170] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 160℃; the speed of the second roller is 605m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.66, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.6; and the temperature of the second heating chamber is 175℃.

[0171] The final sound-insulating polyester composite fiber has a breaking strength of 3.45 cN / dtex, a breaking elongation of 15.4%, an oil content of 2.8%, a crimp shrinkage of 15.2%, a crimp stability of 82.2%, and a fuzz content of 95.8%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.39.

[0172] Comparative Example 10

[0173] The only difference between this method for preparing polyester composite fiber and Example 3 is that the temperature of the first hot box is 165°C.

[0174] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0175] Compared with Example 3, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 10 was significantly reduced. This is because the temperature of the first hot box in Comparative Example 10 was too high, and the filaments of the sound-insulating polyester FDY fiber were prone to breakage, which affected the sound absorption effect of the fabric.

[0176] Example 4

[0177] A method for preparing sound-insulating polyester FDY fiber, the overall process flow is as follows: melt is extruded by metering pump → spinning by spinning assembly → cooling by ring blowing air → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main networking → third guide roller → winding and forming.

[0178] The melt preparation process is as follows: slurry preparation → first esterification → second esterification → prepolymerization → final polymerization → polyester melt (intrinsic viscosity 0.628 dL / g); relevant process parameters are: slurry level 70%, PTA mass in slurry accounts for 71% of the total mass of PTA and EG; first esterification temperature 270℃, first esterification pressure 110kPa, second esterification temperature 277℃, second esterification pressure 38kPa, prepolymerization upper chamber temperature 281℃, prepolymerization upper chamber pressure 40kPa, prepolymerization lower chamber temperature 284℃, prepolymerization lower chamber pressure 2.2kPa, final polymerization inlet temperature 282℃, final polymerization outlet temperature 288℃, final polymerization vacuum degree 240Pa;

[0179] In the spinning assembly, the spinneret has a diameter of 104 mm. The spinnerets on the spinneret are divided into two types, both of which are five-lobed. Each five-lobed spinneret consists of a circle and five long blades radially distributed and connected to the circle. The circle has a diameter of 0.23 mm, and the angle between adjacent blades in the five-lobed shape is 72°. The blades of the first type of spinneret are 0.4 mm long and 0.055 mm wide; the blades of the second type of spinneret are 0.4 mm long and 0.03 mm wide. The centers of all the spinnerets are concentrically distributed on the spinneret, forming a total of five circles. The spinnerets on each circle are evenly distributed. The first circle appearing from the inside out is called the first circle. The diameter of the first circle is 29 mm, and it has 12 second-class spinnerets. The diameter of the second circle is 43 mm, and it has 17 second-class spinnerets. The diameter of the third circle is 57 mm, and it has 23 second-class spinnerets. The diameter of the fourth circle is 71 mm, and it has 29 first-class spinnerets. The diameter of the fifth circle is 85 mm, and it has 35 first-class spinnerets.

[0180] In the spinning assembly, the filter sand is 150g of 50-70 mesh metal sand; the spinning temperature is 290℃.

[0181] The cooling air pressure of the ring-blown cooling system is 40Pa, the length of the cooling air duct is 50cm, and the height of the slow cooling zone is 60mm.

[0182] The first pre-network was located 140cm below the spinneret, and the air pressure of the first pre-network was 0.03MPa.

[0183] The temperature of the first hot roller is 90℃;

[0184] The temperature of the second hot roller is 90℃;

[0185] The speed ratio of the third hot roller to the first hot roller is 2.1;

[0186] The air pressure in the second pre-network was 0.1 MPa;

[0187] The air pressure of the main network is 0.55 MPa.

[0188] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1 cm, and the fibers are curved with a radius of 4 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.01 cN / dtex, a breaking elongation of 30.3%, a differential shrinkage rate of 15.9%, a relative radial anisotropy of 36.7%, an oil content of 0.4%, and a fuzzy fiber content of 96.3%.

[0189] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 83dtex / 72f, physical properties: breaking strength 2.59cN / dtex, breaking elongation 130.9%, evenness CV value 1.14%, oil content 0.34%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0190] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 155℃; the speed of the second roller is 605m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.66, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.62; and the temperature of the second heating chamber is 178℃.

[0191] The final sound-insulating polyester composite fiber has a breaking strength of 3.32 cN / dtex, a breaking elongation of 15.7%, an oil content of 2.8%, a crimp shrinkage of 14.8%, a crimp stability of 79.4%, and a fuzz rate of 96.4%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.49.

[0192] Comparative Example 11

[0193] A method for preparing polyester FDY fiber differs from Example 4 only in that: the diameter of the spinneret is 70 mm; the diameter of the first circle is 22 mm, the diameter of the second circle is 30 mm, the diameter of the third circle is 38 mm, the diameter of the fourth circle is 46 mm, and the diameter of the fifth circle is 54 mm.

[0194] A method for preparing polyester composite fiber differs from Example 4 only in that the sound-insulating polyester FDY fiber prepared in Example 4 is replaced with the polyester FDY fiber prepared in this comparative example.

[0195] The final sound absorption coefficient α of the fabric made from polyester composite fibers is 0.19.

[0196] Compared with Example 4, the sound absorption coefficient α of the fabric made of polyester composite fiber in Comparative Example 11 was significantly reduced. This is because the diameter of the spinneret in Comparative Example 11 was too low, which slowed down the heat dissipation of the plate surface, resulting in a relatively high plate surface temperature and a slower cooling rate. The relative radial irregularity was reduced, and the monofilament B was difficult to form fuzz when passing through the main network, which affected the sound absorption effect of the fabric.

[0197] Example 5

[0198] A method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that all spinneret orifices are distributed on the spinneret as follows: Figure 4 As shown, each rhombus in the figure is identical, with a side length of 7.8 mm and a minimum interior angle of 30°.

[0199] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 0.8 cm, and the fibers are curved with a radius of 3.7 cm. The sound-insulating polyester FDY fiber has a breaking strength of 3.89 cN / dtex, a breaking elongation of 29.7%, an anisotropic shrinkage rate of 15.2%, a relative radial anisotropy of 29.4%, an oil content of 0.39%, and a fuzzy fiber content of 91.5%.

[0200] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 88dtex / 72f, physical properties: breaking strength 2.67cN / dtex, breaking elongation 131.0%, evenness CV value 1.09%, oil content 0.31%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0201] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 160℃; the speed of the second roller is 610m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.67, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.64; and the temperature of the second heating chamber is 182℃.

[0202] The final sound-insulating polyester composite fiber has a breaking strength of 3.39 cN / dtex, a breaking elongation of 14.6%, an oil content of 2.8%, a crimp shrinkage of 14.3%, a crimp stability of 78.6%, and a fuzz rate of 92.9%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.23.

[0203] Example 6

[0204] A method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the mesh size of the metal sand is 70-90.

[0205] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1.0 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.07 cN / dtex, a breaking elongation of 30.1%, a differential shrinkage rate of 15.8%, a relative radial anisotropy of 24.7%, an oil content of 0.4%, and a fuzzy fiber content of 93.1%.

[0206] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 83dtex / 72f, physical properties: breaking strength 2.59cN / dtex, breaking elongation 130.9%, evenness CV value 1.14%, oil content 0.34%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0207] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 157℃; the speed of the second roller is 605m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.66, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.64; and the temperature of the second heating chamber is 185℃.

[0208] The final sound-insulating polyester composite fiber has a breaking strength of 3.34 cN / dtex, a breaking elongation of 15.9%, an oil content of 2.9%, a crimp shrinkage of 15.7%, a crimp stability of 82%, and a fuzz rate of 93.7%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.27.

[0209] Example 7

[0210] A method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the spinning temperature is 295°C.

[0211] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 0.9 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.01 cN / dtex, a breaking elongation of 30.5%, a differential shrinkage rate of 15.8%, a relative radial anisotropy of 25.4%, an oil content of 0.4%, and a fuzzy fiber content of 91.7%.

[0212] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 83dtex / 72f, physical properties: breaking strength 2.59cN / dtex, breaking elongation 130.9%, evenness CV value 1.14%, oil content 0.34%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0213] The polyester POY fiber and the sound-insulating polyester FDY fiber are each in one bundle; the temperature of the first heating box is 154℃; the speed of the second roller is 605m / min, the speed ratio of the second roller to the first roller is 1.66, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.6; the temperature of the second heating box is 180℃.

[0214] The final sound-insulating polyester composite fiber has a breaking strength of 3.37 cN / dtex, a breaking elongation of 15.2%, an oil content of 2.8%, a crimp shrinkage of 15.4%, a crimp stability of 81.9%, and a fuzz rate of 91.6%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.27.

[0215] Example 8

[0216] A method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the cooling air pressure of the ring-blowing cooling is 45 Pa.

[0217] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1.0 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.03 cN / dtex, a breaking elongation of 29.8%, an anisotropic shrinkage rate of 12.4%, a relative radial anisotropy of 38.4%, an oil content of 0.40%, and a fuzzy fiber content of 94.8%.

[0218] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 80dtex / 72f, physical properties: breaking strength 2.54cN / dtex, breaking elongation 130.2%, evenness CV value 1.12%, oil content 0.33%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0219] The polyester POY fiber and the sound-insulating polyester FDY fiber are each in one bundle; the temperature of the first heating box is 155℃; the speed of the second roller is 620m / min, the speed ratio of the second roller to the first roller is 1.65, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.64; the temperature of the second heating box is 182℃.

[0220] The final sound-insulating polyester composite fiber has a breaking strength of 3.39 cN / dtex, a breaking elongation of 15.7%, an oil content of 3.2%, a crimp shrinkage of 14.6%, a crimp stability of 80.3%, and a fuzz rate of 94.1%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.31.

[0221] Example 9

[0222] The method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the length of the cooling duct for ring-blown cooling is 52cm.

[0223] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1.0 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.06 cN / dtex, a breaking elongation of 29.9%, a differential shrinkage rate of 13.7%, a relative radial anisotropy of 36.8%, an oil content of 0.40%, and a fuzzy fiber content of 93.1%.

[0224] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 80dtex / 72f, physical properties: breaking strength 2.54cN / dtex, breaking elongation 130.2%, evenness CV value 1.12%, oil content 0.33%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0225] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 160℃; the speed of the second roller is 620m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.65, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.65; and the temperature of the second heating chamber is 181℃.

[0226] The final sound-insulating polyester composite fiber has a breaking strength of 3.42 cN / dtex, a breaking elongation of 15.6%, an oil content of 2.9%, a crimp shrinkage of 14.3%, a crimp stability of 81.6%, and a fuzz rate of 94.6%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.26.

[0227] Example 10

[0228] A method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the height of the slow cooling zone for ring blowing cooling is 65 mm.

[0229] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1.0 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 4.06 cN / dtex, a breaking elongation of 29.9%, an anisotropic shrinkage rate of 15.1%, a relative radial anisotropy of 31.2%, an oil content of 0.40%, and a fuzzy fiber content of 93.7%.

[0230] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 88dtex / 72f, physical properties: breaking strength 2.67cN / dtex, breaking elongation 131.0%, evenness CV value 1.09%, oil content 0.31%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0231] The polyester POY fiber and the sound-insulating polyester FDY fiber are each in one bundle; the temperature of the first heating box is 158℃; the speed of the second roller is 605m / min, the speed ratio of the second roller to the first roller is 1.67, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.62; the temperature of the second heating box is 183℃.

[0232] The final sound-insulating polyester composite fiber has a breaking strength of 3.39 cN / dtex, a breaking elongation of 14.3%, an oil content of 3%, a crimp shrinkage of 15%, a crimp stability of 82.5%, and a fuzz rate of 94.7%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.25.

[0233] Example 11

[0234] The method for preparing sound-insulating polyester FDY fiber differs from Example 4 only in that the rotational speed ratio of the third hot roller to the first hot roller is 2.0.

[0235] The final sound-insulating polyester FDY fiber has fuzzy fibers distributed on its surface. The length of each fuzzy fiber is 1.0 cm, and the fibers are curved with a radius of 3.9 cm. The sound-insulating polyester FDY fiber has a breaking strength of 3.84 cN / dtex, a breaking elongation of 32.7%, an anisotropic shrinkage rate of 15.6%, a relative radial anisotropy of 36.1%, an oil content of 0.40%, and a fuzzy fiber content of 93.3%.

[0236] A method for preparing sound-insulating polyester composite fiber involves passing polyester POY fiber (specification 88dtex / 72f, physical properties: breaking strength 2.67cN / dtex, breaking elongation 131.0%, evenness CV value 1.09%, oil content 0.31%) and sound-insulating polyester FDY fiber prepared in this embodiment in parallel through a pre-network, a first roller, a first hot box, and a cooling plate. Then, after passing the polyester POY fiber through a false twister, it is twisted together with the sound-insulating polyester FDY fiber at the second roller. Finally, it passes through a network, an auxiliary roller, a second hot box, a third roller, is oiled, and wound to obtain the sound-insulating polyester composite fiber.

[0237] The components consist of one bundle each of polyester POY fiber and sound-insulating polyester FDY fiber; the temperature of the first heating chamber is 157℃; the speed of the second roller is 610m / min, the ratio of the speed of the second roller to the speed of the first roller is 1.68, the ratio of the linear velocity of the friction disc surface of the false twister to the speed of the second roller is 1.63; and the temperature of the second heating chamber is 180℃.

[0238] The final sound-insulating polyester composite fiber has a breaking strength of 3.6 cN / dtex, a breaking elongation of 14.3%, an oil content of 2.8%, a crimp shrinkage of 14.8%, a crimp stability of 80.4%, and a fuzz rate of 92.1%. The sound absorption coefficient α of the fabric made from the sound-insulating polyester composite fiber is 0.22.

Claims

1. A method for preparing sound-insulating polyester FDY fiber, comprising a spinning assembly spinning process, a ring blowing cooling process, a stretching process, a setting process, and a main network process, characterized in that, In the spinning assembly, the number of spinneret holes on the spinneret is 96-144, which are divided into two categories; Both types of spinnerets are five-lobed, consisting of a circle and five long blades that are connected to the circle and distributed radially. The diameter of the circle is 0.23±0.01mm, and the included angle between two adjacent blades is 72°. The first type of spinneret has a blade length of 0.4 mm and a blade width of 0.055 mm; the second type of spinneret has a blade length of 0.4 mm and a blade width of 0.03 mm. The ratio of the number of type I spinnerets to the number of type II spinnerets is 1-2:1; The diameter of the spinneret is 95-105mm; The stretching is accomplished by the first hot roller, the second hot roller and the third hot roller together, with the temperature of the first hot roller and the second hot roller being 90-94℃; The shaping process is completed jointly by the third and fourth hot rollers. The air pressure in the main network is 0.55-0.6 MPa.

2. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, All the spinnerets are arranged in concentric circles on the spinneret. The first type of spinnerets are arranged on the outer circle of the spinneret, and the second type of spinnerets are arranged on the inner circle of the spinneret.

3. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, In the spinning assembly, the filter sand is 150-180g, 50-70 mesh metal sand.

4. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, The spinning temperature is 286-290℃.

5. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, The cooling air pressure for the ring-blown cooling system is 35-40Pa, the length of the cooling duct is 48-50cm, and the height of the slow cooling zone is 55-60mm.

6. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, The speed ratio of the third hot roller to the first hot roller is 2.0-2.

5.

7. The method for preparing sound-insulating polyester FDY fiber according to claim 1, characterized in that, The overall process flow is as follows: melt is extruded by metering pump → spinning assembly → ring blowing cooling → first oiling → first pre-networking → first guide roller → first hot roller → second hot roller → third hot roller → fourth hot roller → second guide roller → second oiling → second pre-networking → main network → third guide roller → winding and forming.

8. The method for preparing sound-insulating polyester FDY fiber according to claim 7, characterized in that, The first pre-network is located 130-140cm below the spinneret, with an air pressure of 0.03-0.04MPa. The second pre-network has an air pressure of 0.1-0.15MPa.

9. The sound-insulating polyester FDY fiber prepared by the method for preparing sound-insulating polyester FDY fiber according to any one of claims 1 to 8, characterized in that, The surface is covered with fuzzy fibers, the length of which is 0.5-1.0 cm. The fibers are curved with a radius of 2-4 cm. The sound-insulating polyester FDY fiber has a breaking strength ≥3.84 cN / dtex, a breaking elongation of 28.8-32.7%, a differential shrinkage rate of 12.4-18.2%, a relative radial anisotropy ≥24.7%, an oil content of 0.39-0.45%, and a fuzzy fiber rate ≥91.5%.

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