A method for the production of self-colored recycled bicomponent pes yarn compatible with harsh weather conditions

Abstract

The invention relates to a self-colored recycled bicomponent PES yam production method suitable for use in outdoor textile materials.

Description

[0001] A METHOD FOR THE PRODUCTION OF SELF-COLORED RECYCLED BICOMPONENT PES YARN COMPATIBLE WITH HARSH WEATHER CONDITIONS

[0002] Technical Field

[0003] The invention relates to a self-colored recycled bicomponent PES yam production method suitable for use in outdoor textile materials.

[0004] State of the Art

[0005] Outdoor textiles are used in areas requiring high light and outdoor and climatic conditions such as awnings, tarpaulin, sunshades, outdoor curtains, outdoor seating groups, cushions, garden furniture, and sunbed. The fabrics used in these outdoor applications have high resistance to external climatic changes such as sunlight, rain, and wind and have high strength.

[0006] In the present art, yarns obtained from acrylic fibers are used to weave the fabrics used in outdoor applications. Due to its acrylic fiber structure, it naturally resists the corrosive effect of UV rays and is therefore frequently preferred in the production of outdoor textiles. However, it is becoming more and more difficult to provide due to the high cost.

[0007] In addition, in parallel with the increase in environmentally friendly activities, in recent years, the circular economy, a new production model based on sustainability and innovation, has become increasingly important, where every waste generated in a production system is reevaluated, thus minimizing the cost of raw materials, and maximizing resource efficiency and environmental benefit. In the prior art, three different ways of recycling polyesters can be used: physical / mechanical recycling, semi-physical recycling, and chemical recycling. Physical / mechanical recycling is widely used especially in the recycling of pet bottles. After the collected pet bottles are washed with various detergents, they are broken and sold as flakes (small pieces). Impurities such as polyethylene in it are separated by different densities. PVC impurities are largely physically separated by PVC detectors. Semi-physical recycling method is used to make the product more homogeneous. Pet vials are melted by extruding and the resulting melt pet is passed through polymer filters to obtain a cleaner and homogeneous polymer. Another recycling activity applied today is the transformation of textile products into various semi-finished and finished products to be used in many sectors by using different recycling methods instead of disposing of garment wastes that are seen as wasted and formed in the production process.

[0008] Changing economic conditions and environmental factors lead manufacturers to develop and produce different fabric structures resistant to ultraviolet rays. In the patent application EP2377991B1, which is one of the studies on the subject, at least one ultraviolet-resistant additive and fabric containing flame-resistant fibers by nature, which are included in flameresistant fibers by nature, are described. In the relevant application, it is stated that flameresistant fibers contain aramid fibers and at least one ultraviolet-resistant additive is incorporated into the fibers by a dyeing process using a carrier.

[0009] The invention of patent application WO2021158196A1 relates to increasing the UV light and surface heating resistance of acrylic fibers containing at least 85% acrylonitrile groups or modacrylic fibers containing at least 40% acrylonitrile groups and at least 40% vinylidene chloride groups produced for use in outdoor textiles.

[0010] In said applications, fabrics made of different raw materials are given protective properties against UV rays by using different methods. In the process steps of the mentioned methods, there are harmful wastes to human and environmental health. The aforementioned methods, labor, time, and chemicals used cannot reduce the costs to the desired levels in terms of inputs.

[0011] Consequently, due to the aforementioned problems and deficiencies, there has been a need to make an innovation in the related technical field.

[0012] Objects of the Invention

[0013] The present invention relates to a method of producing self-colored, recycled bicomponent PES yarn that meets the aforementioned requirements, eliminates all disadvantages, and provides some additional advantages thereof. The object of the invention is to provide a method of producing recycled bicomponent PES yarn with increased resistance to UV rays, eliminating the need for coloring.

[0014] The object of the invention is to realize the coloring and increase the resistance to UV rays of bicomponent PES yams obtained from recycled plastic chips in a single process step and to ensure that its performance is higher than the current UV production technology.

[0015] The object of the invention is to reduce the use of dyestuff and chemical additives to be used in the colored bicomponent PES yam production process with increased resistance to UV rays.

[0016] The object of the invention is to eliminate the waste in the process by shortening the production processes. Thus, an environmentally friendly production process is ensured.

[0017] An object of the invention is to eliminate chemical and dyestuff wastes used in yarn or fabric dyeing processes.

[0018] An object of the invention is to reduce labor, production time, and cost.

[0019] The invention is a self-color recycled bicomponent PES yam production method used in outdoor textile materials in order to fulfill the abovementioned objects, characterized in that it comprises the following process steps:

[0020] • providing recycled chips obtained from waste plastic products,

[0021] • keeping the chips in the drying silo A and drying silo B with hot air between 150- 165°C with the help of a horizontal crystallizer with static and ultra-dry air supply until the moisture content of the chips falls below 50 ppm,

[0022] • feeding the recycled PES chips with the desired moisture level to the extruder filling chamber A heated to 280-300°C in equal proportions (1 : 1) and to the extruder filling chamber B heated to 280-295°C with the help of an automatic system,

[0023] • increasing the resistance of the yam to UV rays and coloring the yam, adding masterbatch to the extruder filling chamber A, and UV additive in the form of masterbatch with PBT carrier to the extruder filling chamber B, • melting of the chips while transporting them with the help of endless extruder screws in the extruder filling chamber A and extruder filling chamber B,

[0024] • ensuring the transfer of melted recycled PES polymers by passing them through the filter with 100-200 bar,

[0025] • feeding the recycled PES polymers to the nozzle at a certain speed with the melt pump and providing regular flow with 110-210 bar through the holes in the nozzle,

[0026] • cooling the melt coming out of the nozzle holes with 60-80% humid air at 15-30°C sent by the cooling chamber,

[0027] • lubricating the cooled recycled bicomponent filaments with anti-static antielectrification oils by passing through the lubrication wheel,

[0028] • wrapping the post-lubrication filaments around godet 1 heated to 80-120°C and godet 2 heated to 100-140°C, respectively, to increase the crystalline regions in the structure by applying gravity on them,

[0029] • applying draft to the yam with the ratio of godet 2 speed to godet 1 speed in the range of 1.5-5 times,

[0030] • wrapping the obtained bicomponent PES yam on godet3 to fix its structure.

[0031] In order to realize the objects of the invention, 65% recycled chips and 1-4% masterbatch are added to the extruder filling chamber A, and 35% recycled chips and 3-5% UV additive in the form of PBT carrier masterbatch are added to the extruder filling chamber B.

[0032] In order to achieve the objects of the invention, in the method, all pipes through which the melt passes from extruder filling chamber A and extruder filling chamber B to the outlet of the nozzle are protected at constant temperature by heat transfer oil vapor evaporating at 256°C.

[0033] The structural and characteristic features of the present invention will be understood clearly by the following detailed description and therefore the evaluation shall be made by considering the detailed description.

[0034] Figures for a Better Understanding of the Invention

[0035] Figure 1: General view of an assembly for the production of the yam of the invention. The figures are not required to be scaled, and the details which are not necessary to understand the present invention may be ignored. Furthermore, parts that are at least substantially identical or have at least substantially identical functions are indicated by the same number.

[0036] Description of the Part References

[0037] 1. Drying silo A

[0038] 2. Drying silo B

[0039] 3. Extruder filling chamber A

[0040] 4. Extruder filling chamber B

[0041] 5. Extruder screw

[0042] 6. Filter

[0043] 7. Melt pump

[0044] 8. Nozzle

[0045] 9. Cooling chamber

[0046] 10. Lubrication wheel

[0047] 11. Godet 1

[0048] 12. Godet2

[0049] 13. Godet3

[0050] Detailed Description of the Invention

[0051] In this detailed description, a method for the production of self-colored recycled bicomponent PES yam, compatible with harsh weather conditions, is described only for a better understanding of the subject matter and in a non-limiting manner.

[0052] The invention relates to a self-colored recycled bicomponent PES yam production method suitable for use in outdoor textile materials.

[0053] The recycled bicomponent PES yarn production method of the invention comprises the following process steps:

[0054] • providing recycled chips obtained from waste plastic products, • keeping the chips in the drying silo A (1) and drying silo B (2) with hot air between 150-165°C with the help of a horizontal crystallizer with static and ultra-dry air supply until the moisture content of the chips falls below 50 ppm,

[0055] • feeding the recycled PES chips with the desired moisture level to the extruder filling chamber A (3) heated to 280-300°C in equal proportions (1 : 1) and to the extruder filling chamber B (4) heated to 280-295°C with the help of an automatic system,

[0056] • increasing the resistance of the yarn to UV rays and coloring the yarn, masterbatch w to the extruder filling chamber A (3), and UV additive in the form of masterbatch with PBT carrier to the extruder filling chamber B (4),

[0057] • melting of the chips while transporting them with the help of endless extruder screws (5) in the extruder filling chamber A (3) and extruder filling chamber B (4),

[0058] • ensuring the transfer of melted recycled PES polymers by passing them through the filter (6) with 100-200 bar,

[0059] • feeding the recycled PES polymers to the nozzle (8) at a certain speed with the melt pump (7) and providing regular flow with 110-210 bar through the holes in the nozzle (8),

[0060] • cooling the melt coming out of the nozzle (8) holes with 60-80% humid air at 15-30°C sent by the cooling chamber (9),

[0061] • lubrication of the cooled recycled bicomponent filaments with anti-static antielectrification oils by passing through the lubrication wheel (10),

[0062] • wrapping the post-lubrication filaments around godet 1 heated to 80-120°C and godet 2 heated to 100-140°C, respectively, to increase the crystalline regions in the structure by applying gravity on them,

[0063] • applying draft to the yam with the ratio of godet 2 speed to godet 1 speed in the range of 1.5-5 times,

[0064] • wrapping the obtained bicomponent PES yam on godet3 (13) to fix its structure.

[0065] Figure 1 shows the general view of an assembly for the production of the yam of the invention.

[0066] When recycled chips undergo moisture change, problems in stability may occur at the time of production. In order to prevent this disadvantage, in the production method according to the invention, the moisture ratios of the chips are absolutely reduced to below 50 ppm. In the method of the invention, all pipes through which the melt passes from extruder filling chamber A (3) and extruder filling chamber B (4) to the nozzle (8) are protected at a constant temperature with heat transfer oil vapor evaporating at 256°C.

[0067] In the method of the invention, yarn extraction is adjusted, and orientation is performed with the ratio of godet 2 speed to godet 1 being in the range of 1.5-5 times.

[0068] In the method of the invention, the recycled PES yarn, which reaches the highest levels of a crystalline structure after shooting, is wound on the coils at a rate of 4000-4600 m / min through the winding unit. With this extraction method, the yarn is brought to the FDY (Fully Drawn Yam) form. All conditions from the drying of the crystallizer to the godets are used in the same way and wrapped in yam coils in the form of POY (Partially Oriented Yam) with 2900-33 OOm / min fast cold godets and 2900-33 OOm / min winding speed.

[0069] The obtained yams were tested based on ISO 105 B04 standard and color fastness and loss of strength were examined. The Grade result was found to be between 7-8 according to the color fastness test. As can be seen from this result, a large change in color fastness was observed compared to the existing yams.

[0070] In obtaining recycled bicomponent PES yarn with increased UV resistance and self-colored recycled PES yam of the invention, 65% recycled chips, and 1-4% masterbatch were added to extruder filling chamber A (3), and 35% recycled chips and 3-5% UV additive in the form of PBT carrier masterbatch were added to extruder filling chamber B (4).

Claims

CLAIMS A self-colored recycled bicomponent PES yarn production method used in outdoor textile materials, suitable for harsh weather conditions, characterized in that it comprises the following process steps: a. providing recycled chips obtained from waste plastic products, b. keeping the chips in the drying silo A (1) and drying silo B (2) with hot air between 150-165°C with the help of a horizontal crystallizer with static and ultra-dry air supply until the moisture content of the chips falls below 50 ppm, c. feeding the recycled PES chips with the desired moisture level to the extruder filling chamber A (3) heated to 280-300°C in equal proportions (1 : 1) and to the extruder filling chamber B (4) heated to 280-295°C with the help of an automatic system, d. increasing the resistance of the yam to UV rays and coloring the yarn, adding masterbatch to the extruder filling chamber A (3), and UV additive in the form of masterbatch with PBT carrier to the extruder filling chamber B (4), e. melting of the chips while transporting them with the help of endless extruder screws (5) in the extruder filling chamber A (3) and extruder filling chamber B (4), f. ensuring the transfer of melted recycled PES polymers by passing them through the filter (6) with 100-200 bar, g. feeding the recycled PES polymers to the nozzle (8) at a certain speed with the melt pump (7) and providing regular flow with 110-210 bar through the holes in the nozzle (8), h. cooling the melt coming out of the nozzle (8) holes with 60-80% humid air at 15- 30°C sent by the cooling chamber (9), i. lubricating the cooled recycled bicomponent filaments with anti-static antielectrification oils by passing through the lubrication wheel (10), j. wrapping the post-lubrication filaments around godet 1 (11) heated to 80-120°C and godet 2 (12) heated to 100-140°C, respectively, to increase the crystalline regions in the structure by applying gravity on them, k. applying draft to the yarn with the ratio of godet 2 speed to godet 1 speed in the range of 1.5-5 times, l. wrapping the obtained bicomponent PES yam on godet3 (13) to fix its structure.A production method according to Claim 1, characterized in that it comprises the process step of adding 65% recycled chips and 1-4% masterbatch to extruder filling chamber A (3), 35% recycled chips, and 3-5% UV additive in the form of PBT carrier masterbatch to extruder filling chamber B (4) in the d process step. A production method according to Claim 1, characterized in that it comprises the process step of protecting 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 with the heat transfer oil vapor evaporating at 256°C.

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