SPINNING METHOD, SPINNING MACHINE, AND YARN

Abstract

 A spinning method for forming a yarn by twisting a fiber bundle by the action of a swirling current of air includes mixing and spinning. The mixing includes mixing an agent with the air. The spinning includes twisting the fiber bundle by the action of the agent-containing air. The fiber bundle includes at least one of natural fibers, regenerated fibers, semisynthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present invention relates to a spinning method, a spinning machine, and a yarn.

2. Description of the Related Art

[0002] Spinning machines that twist a fiber bundle by the action of a swirling current of air to form a yarn are known in the art. In such a spinning machine, the problem described below is encountered when synthetic fibers, such as polyester, are used as a raw material for forming a spun yarn. An oiling agent is typically applied to the synthetic fibers to allow drawing and spinning processes to proceed favorably and smoothly and to enhance and stabilize the quality of the synthetic fibers. However, during the twisting of the synthetic fibers in an air-jet spinning device, the oiling agent applied to the synthetic fibers tends to get deposited inside the air-jet spinning device. When the trailing fiber ends of the fiber bundle are whirled by the swirling current of the air, the deposited oiling agent hinders the turning of the trailing fiber ends, preventing them from turning adequately. Consequently, a so-called weak yarn having a low tenacity may be formed.

[0003] To address the above problem, Japanese Patent Applicant Laid-open No. 2008-95208 discloses a spinning device in which a surfactant is mixed with the air when twisting synthetic fibers, such as polyester, that contain an oiling agent, with a swirling current of air. In the spinning device disclosed in the above patent document, the surfactant prevents the oiling agent present in the synthetic fiber from being deposited in the air-jet spinning device.

[0004] Aside from synthetic fibers, various other types of fibers can serve as raw materials for forming fiber bundles. There is a need to enhance the quality of the yarn formed from a fiber bundle composed of these raw materials.

SUMMARY OF THE INVENTION

[0005] It is an object of the present invention to provide a spinning method and a spinning machine that can produce a yarn having enhanced quality.

[0006] A spinning method according to an aspect of the present invention is a method for forming a yarn by twisting a fiber bundle by the action of a swirling current of air, and includes mixing an agent with the air; and spinning including twisting the fiber bundle by the action of the agent-containing air, wherein the fiber bundle includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers.

[0007] A spinning machine according to still another aspect of the present invention forms the yarn from the fiber bundle that includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers, and includes a drafting device that drafts the fiber bundle; an air-jet spinning device that twists the fiber bundle drafted by the drafting device by the action of a swirling current of air and forms the yarn; an agent supplying device that mixes an agent with the air; and a winding device that winds the yarn formed by the air-jet spinning device.

[0008] A yarn according to still another aspect of the present invention is formed by the above spinning method.

[0009] A spinning method according to still another aspect of the present invention forms the yarn by twisting the fiber bundle by the action of the swirling current of air, and includes mixing an agent with the air; and spinning including twisting the fiber bundle by the action of the agent-containing air, wherein the fiber bundle includes at least one raw material having a lower Young's modulus than that of polyester.

[0010] The above and other objects, features, advantages and the technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 

FIG. 1 is a drawing of a spinning machine according to an embodiment of the present invention.

FIG. 2 is a side view of a spinning unit of the spinning machine shown in FIG. 1.

FIG. 3 is a cross-sectional view of an air-jet spinning device.

FIG. 4 is a drawing of an air distributing device and an agent supplying device.

FIG. 5 is a table of evaluation results.

FIG. 6 is a graph for explaining a relationship between an elongation degree and a tenacity depicted by tenacity-elongation curves.

DETAILED DESCRIPTION

[0012] Exemplary embodiments of the present invention are explained in detail below with reference to the accompanying drawings. Identical parts or equivalent parts in these drawings are denoted by the same reference symbols, and redundant description is omitted.

[0013] As shown in FIG. 1, a spinning machine 1 includes plural spinning units 2, a yarn joining carrier 3, a blower box 4, a motor box 5, and a main controller (control unit) 100.

[0014] The spinning units 2 are arranged side by side. Each spinning unit 2 forms a spun yarn Y and winds the spun yarn Y into a package P. The yarn joining carrier 3 performs yarn joining in the spinning unit 2 in which a breakage of the spun yarn Y has occurred. The blower box 4 houses an air supplying source, and the like, that generates a suction air current, a swirling current, and the like, in the component parts of the spinning unit 2. The motor box 5 houses a motor, and the like, that supplies power to the component parts of the spinning unit 2. The main controller 100 controls the overall operation of the spinning machine 1.

[0015] In the following explanation, on a traveling route of the spun yarn Y (that is, on a yarn route), the side where the spun yarn Y is formed shall be referred to as upstream, and the side where the spun yarn Y is wound shall be referred to as downstream. Moreover, with respect to the yarn joining carrier 3, the side where the yarn route is located shall be referred to as the front side and the opposite side thereof shall be referred to as the backside. A not shown working passage that extends in an arrangement direction of the spinning units 2 is present on the front side of the spinning machine 1. The device operator can operate, monitor, and the like, each of the spinning units 2 from the working passage.

[0016] As shown in FIGS. 1 and 2, each of the spinning units 2 includes, sequentially from upstream, a drafting device 6, an air-jet spinning device 7, a yarn clearer 8, a tension sensor 9, a yarn pooling device 10, a waxing device 11, and a winding device 12. These devices are directly or indirectly supported by a not shown machine frame such that the upper side of the machine in a height direction corresponds to upstream (that is, the lower side of the machine in the height direction corresponds to downstream).

[0017] The drafting device 6 drafts a fiber bundle S. The drafting device 6 includes, sequentially from upstream (the side on a conveyance path of the fiber bundle S from where the fiber bundle S is supplied), a fiber bundle guide 60, a back roller pair 61, a third roller pair 62, a middle roller pair 64 with an apron belt 63 stretched over each roller of the middle roller pair 64, and a front roller pair 65.

[0018] The air-jet spinning device 7 twists the fiber bundle S drafted by the drafting device 6 by the action of a swirling current of the air and forms the spun yarn Y. The yarn clearer 8 monitors the traveling spun yarn Y at a location between the air-jet spinning device 7 and the yarn pooling device 10, and on detecting a yarn defect, transmits a yarn defect detection signal to a unit controller C. The yarn clearer 8 detects, for example, any thickness abnormality of the spun yarn Y and/or presence of foreign substance in the spun yarn Y as yarn defects. The tension sensor 9 measures a tension of the traveling spun yarn Y at a location between the air-jet spinning device 7 and the yarn pooling device 10, and transmits the measured tension as a tension measurement signal to the unit controller C. The yarn pooling device 10 pools the traveling spun yarn Y at a location between the air-jet spinning device 7 and the winding device 12. The waxing device 11 applies wax to the traveling spun yarn Y at a location between the yarn pooling device 10 and the winding device 12. The unit controller C is arranged for each spinning unit 2 and controls the operation of the spinning unit 2. The unit controller C is controlled by the main controller 100.

[0019] The winding device 12 winds the spun yarn Y formed by the air-jet spinning device 7 to form the package P. The winding device 12 includes a cradle arm 21, a winding drum 22, and a traverse device 23. The cradle arm 21 is swingably supported by a shaft 24 and brings a surface of a rotatably supported bobbin B or package P (that is, the bobbin B with the spun yarn Y wound thereon) into contact with a surface of the winding drum 22 with an appropriate pressure. The winding drum 22 is driven by a not shown electric motor arranged for each spinning unit 2. In an alternative structure, the winding drum 22 can be driven by a shaft that is shared by plural spinning units 2. The bobbin B or the package P that is in contact with the winding drum 22 rotates following the rotation of the winding drum 22. The traverse device 23 is driven by a shaft 25 that is shared by plural spinning units 2, and traverses the spun yarn Y within a given width over the rotating bobbin B or the package P.

[0020] The yarn joining carrier 3 moves to the spinning unit 2 in which a breakage of the spun yarn Y has occurred and performs the yarn joining operation in that spinning unit 2. The yarn joining carrier 3 includes a splicer 26, a suction pipe 27, and a suction mouth 28. The suction pipe 27 is swingably supported by a shaft 31, and sucks and catches a yarn end of the spun yarn Y from the air-jet spinning device 7 and guides the caught yarn end to the splicer 26. The suction mouth 28 is swingably supported by a shaft 32, and sucks and catches a yarn end of the spun yarn Y from the winding device 12 and guides the caught yarn end to the splicer 26. The splicer 26 joins the two yarn ends that are guided thereto.

[0021] A touch panel display 102 is connected to the main controller 100. The touch panel display 102 displays information pertaining to settings and operation states of the spinning machine 1 and accepts input from the device operator. The touch panel display 102 functions as a display unit and an input unit. The touch panel display 102 displays a display screen based on display information received from the main controller 100. In response to a touch operation performed on the display screen by the device operator, the touch panel display 102 outputs the operation information to the main controller 100.

[0022] The main controller 100 causes the touch panel display 102 to display a display screen for inputting a type of raw material of the fiber bundle S. The device operator can input the type of raw material of the fiber bundle S by selecting one from among plural types displayed on the display screen or by directly inputting the type of raw material with a keyboard displayed on the touch panel display 102. Upon receiving the operation information indicating the type of raw material of the fiber bundle S output from the touch panel display 102, the main controller 100 controls a later-explained agent supplying device 50 and adjusts a mixing quantity of an agent.

[0023] The air-jet spinning device 7 is explained below in greater detail. As shown in FIG. 3, the air-jet spinning device 7 includes a fiber guide (fiber guiding member) 71, a hollow guide shaft 72, a nozzle block (spinning nozzle member) 73, and a spinning chamber SC. The solid arrows in FIG. 3 indicate a conveyance direction of the fiber bundle S and the spun yarn Y. The hollow arrows in FIG. 3 indicate a flow direction of the agent-containing air.

[0024] A fiber guiding route 71g is formed in the fiber guide 71. The fiber guide 71 guides the fiber bundle S drafted by the drafting device 6 to the spinning chamber SC. A needle 71n along which the fiber bundle S is guided is arranged in the fiber guide 71 so as to protrude into the spinning chamber SC.

[0025] A fiber passageway 72s is formed in the hollow guide shaft 72. The hollow guide shaft 72 guides the fiber bundle S twisted in the spinning chamber SC, that is the spun yarn Y, to the outside of the air-jet spinning device 7 (for example, to the yarn clearer 8).

[0026] The nozzle block 73 guides the air that is press-fed by a later-explained air pressurizing and supplying device 41 to the spinning chamber SC. In the nozzle block 73, the air is guided into the spinning chamber SC through air holes 73a that communicate with the spinning chamber SC. The air holes 73a arranged in the nozzle block 73 communicate with the spinning chamber SC such that the air blown out from the air holes 73a flows in the same direction, about the central axis of the spinning chamber SC, and thereby the swirling current of the air is generated inside the spinning chamber SC (indicated by the hollow arrows in FIG. 3).

[0027] The spinning chamber SC is explained in detail below. The spinning chamber SC is a space surrounded by the fiber guide 71, the hollow guide shaft 72, and the nozzle block 73. The spinning chamber SC is divided into a space SC1 that is formed between the fiber guide 71 and the hollow guide shaft 72 and a space SC2 that is formed between the hollow guide shaft 72 and the nozzle block 73. In the space SC1, the trailing fiber ends of the fiber bundle S are reversed and whirled by the swirling current (indicated by the double-dashed chain lines in FIG. 3). In the space SC2, the reversed and whirled trailing fiber ends are whirled by the swirling current (indicated by the double-dashed chain lines in FIG. 3).

[0028] With the above structure, the trailing fiber ends of the fiber bundle S guided along the needle 71n are whirled and wound over the central fibers in succession. In this manner, the air-jet spinning device 7 twists the fiber bundle S by the action of the swirling current of the air to form the spun yarn Y. In an alternative configuration, the fiber guide 71 of the air-jet spinning device 7 can be devoid of the needle 71n, and the function of the needle 71n can be realized by the edge at the downstream end of the fiber guide 71.

[0029] As shown in FIG. 4, the spinning machine 1 includes an air distributing device 40 and the agent supplying device 50. The air distributing device 40 includes the air pressurizing and supplying device 41, a first air pipe 42, first distribution pipes 43, a second air pipe 44, and second distribution pipes 45.

[0030] The air pressurizing and supplying device 41 pressurizes and supplies the air. The air pressurizing and supplying device 41 is, for example, an electric compressor that pressurizes air by the action of an electric motor that is driven. A pressure of the pressurized air supplied by the air pressurizing and supplying device 41 is adjusted by a pressure adjusting valve 41a. The air pressurizing and supplying device 41 is arranged, for example, in the blower box 4.

[0031] The first air pipe 42 guides the air pressurized and supplied by the air pressurizing and supplying device 41. The first air pipe 42 is mounted parallel to or substantially parallel to an arrangement direction of the spinning units 2.

[0032] The first distribution pipe 43 diverges and guides the air flowing through the first air pipe 42 to the air-jet spinning device 7. One end of the first distribution pipe 43 is connected to the air-jet spinning device 7. The other end of the first distribution pipe 43 is connected to the midway portion of the first air pipe 42. In this manner, the first distribution pipe 43 diverges and guides the air flowing through the first air pipe 42 to the air-jet spinning device 7. A flow amount of the air guided to the air-jet spinning device 7 by the first distribution pipe 43 is adjusted by an opening/closing valve 43a arranged in the first distribution pipe 43.

[0033] The second air pipe 44 guides the air pressurized and supplied by the air pressurizing and supplying device 41. The second air pipe 44 is mounted parallel to or substantially parallel to the arrangement direction of the spinning units 2.

[0034] The second distribution pipe 45 diverges and guides the air flowing through the second air pipe 44 to the air-jet spinning device 7. One end of the second distribution pipe 45 is connected to the air-jet spinning device 7. The other end of the second distribution pipe 45 is connected to the midway portion of the second air pipe 44. In this manner, the second distribution pipe 45 diverges and guides the air flowing through the second air pipe 44 to the air-jet spinning device 7. A flow amount of the air guided to the air-jet spinning device 7 by the second distribution pipe 45 is adjusted by an opening/closing valve 45a arranged in the second distribution pipe 45.

[0035] With the above structure, the air distributing device 40 supplies the air pressurized and supplied by the air pressurizing and supplying device 41 to the air-jet spinning device 7 via the first air pipe 42 or the second air pipe 44. In an alternative structure, the second air pipe 44 can be omitted. In another alternative structure, a more air pipes can be arranged than there are in the spinning machine 1 according to the present embodiment.

[0036] As shown in FIG. 4, the agent supplying device 50 includes a diverging pipe 51, a pressure adjusting device 52, an agent storage tank (storage unit) 53, and an agent supplying pipe (spraying unit) 54.

[0037] The diverging pipe 51 diverges and guides the air flowing through the first air pipe 42 to the agent storage tank 53. One end of the diverging pipe 51 is connected to the agent storage tank 53. The other end of the diverging pipe 51 is connected to the mid portion of the first air pipe 42. In this manner, the diverging pipe 51 diverges and guides the air flowing through the first air pipe 42 to the agent storage tank 53.

[0038] The pressure adjusting device 52 pressurizes the air guided to the agent storage tank 53 and adjusts an internal pressure of the agent storage tank 53. The pressure adjusting device 52 is, for example, a pressure boosting valve that pressurizes the air by the action of a sliding piston that is driven. Alternatively, the pressure adjusting device 52 can be an electric compressor that pressurizes the air by the action of an electric motor that is driven. The pressure adjusting device 52 is connected to the main controller 100 via an electric circuit. The main controller 100 controls the pressure adjusting device 52 by transmitting a control signal to the pressure adjusting device 52.

[0039] The agent storage tank 53 is a vessel for storing the agent. In the present embodiment, the agent is, for example, a lubricant. The agent, however, is not limited to lubricants; any of various other agents can be used. The agent storage tank 53 includes a level sensor 53a that detects a quantity of the agent in the agent storage tank 53. The level sensor 53a is connected to the main controller 100 via an electric circuit. The main controller 100 monitors the quantity of the agent in the agent storage tank 53 based on a detection signal received from the level sensor 53a.

[0040] The agent supplying pipe 54 guides the agent stored in the agent storage tank 53 to the first air pipe 42. One end of the agent supplying pipe 54 is connected so as to open at the bottom of the agent storage tank 53. The other end of the agent supplying pipe 54 is connected to the upstream side where the air flowing through the first air pipe 42 diverges towards each of the air-jet spinning devices 7.

[0041] With the above structure, the agent supplying device 50 sprays the agent stored in the agent storage tank 53 into the first air pipe 42. In the agent supplying device 50 the mixing quantity of the agent can be controlled by adjusting the pressure adjusting device 52. The agent supplying device 50 is controlled by the main controller 100. The main controller 100 controls the mixing quantity of the agent by controlling the agent supplying device 50 in accordance with the raw material of the fiber bundle S.

[0042] By opening a valve 46 arranged in the upstream part of the first air pipe 42 and closing a valve 48 arranged in the air pipe 47, the air distributing device 40 supplies air to the air-jet spinning device 7 only through the first air pipe 42. By this action, the air distributing device 40 supplies only the agent-containing air to the air-jet spinning device 7. By closing the valve 46 and opening the valve 48, the air distributing device 40 supplies air to the air-jet spinning device 7 only through the second air pipe 44. By this action, the air distributing device 40 supplies only an agent-free air to the air-jet spinning device 7. Alternatively, when supplying only the agent-containing air, a valve 49 arranged in the upstream part of the second air pipe 44 can be closed instead of the valve 48. As an alternative configuration, either one of the valves 48 and 49 can be arranged.

[0043] The fiber bundle S spun with the spinning machine 1 having the above structure includes at least the following raw materials. That is, the raw material of the fiber bundle S includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers. Natural fibers, for example, can be seed hair fibers or bast fibers, and concretely can be cotton, flax, and the like. As a modification, cotton can be excluded from the natural fibers. Regenerated fibers, for example, can be regenerated cellulose-based, and concretely can be rayon, special rayon (polynosic or HWM rayon), cupra, and the like. Semi-synthetic fibers, for example, can be cellulose-based, and concretely can be acetate, triacetate, and the like. Polyamide-based fibers, for example, can be nylon. Polyacrylonitrile-based fibers, for example, can be acrylic, acrylic-based, and the like.

[0044] A spinning method that is adopted in the spinning machine 1 is explained below. First, the device operator inputs the type of raw material of the fiber bundle S through the touch panel display 102. In response to the input type of raw material of the fiber bundle S, the main controller 100 controls the mixing quantity of the agent in the agent supplying device 50.

[0045] The fiber bundle S is drafted by the drafting device 6 and conveyed to the air-jet spinning device 7. The air distributing device 40 and the agent supplying device 50 supply the agent-containing air in the form of mist to the air-jet spinning device 7. The air-jet spinning device 7 forms the spun yarn Y by twisting the fiber bundle S by the action of swirling current of the agent-containing air. During this action, in the air-jet spinning device 7, any oily substance (oiling agent), and the like, present in the fiber bundle S that may have been deposited in the hollow guide shaft 72 in the form of deposits (stain) is removed by the action of the agent and the swirling current. In the present embodiment, the air-jet spinning device 7 forms the spun yarn Y at a rate, for example, ranging from 300 m/min to 600 m/min. The spun yarn Y formed by the air-jet spinning device 7 is wound into the package P by the winding device 12.

[0046] As explained above, in the spinning method executed on the spinning machine 1, the fiber bundle S includes as a raw material at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers. When the fiber bundle S that includes the above raw materials is subjected to air-jet spinning by the action of the agent-containing air, the friction resistance between the fibers is increased due to the presence of the agent, leading to an increased convergence between the fibers. Consequently, the fibers are brought together tightly, resulting in a reduced diameter of the spun yarn Y. Furthermore, the friction resistance between the fiber bundle S and the hollow guide shaft 72 of the air-jet spinning device 7 is reduced due to the presence of the agent. Consequently, the trailing fiber ends of the fiber bundle S ride the air current and are whirled at a high speed, resulting in more fibers being wound on the outer side of the fiber bundle S and more fuzz. Hence, the quality of the spun yarn Y being formed with the spinning machine 1 can be enhanced.

[0047] With the spinning method according to the present embodiment, the spun yarn Y having a small diameter (a tightly twisted spun yarn Y), that is, a spun yarn Y that is strong against squeezing, is formed. Consequently, a spun yarn Y having a predetermined tenacity can be formed even if a spinning speed is increased. Hence, by adopting the spinning method according to the present embodiment, a productivity of the spun yarn Y can be enhanced.

[0048] FIG. 5 is a table for explaining evaluation results of evaluations of the spun yarn Y formed in the spinning machine 1. A lubricant is used as the agent. A comparison with a case where the agent is not mixed is shown in the evaluation results shown in FIG. 5. The term "Rollability" in FIG. 5 is an index of a binding strength of the spun yarn Y against the spinning speed, and this property is measured with a rolling testing device.

[0049] As shown in FIG. 5, the rollability of a fiber bundle that includes viscose rayon and acetate as raw materials is enhanced by 40 m/min to 60 m/min. That is, a 10% to 15% increase in the rollability can be demonstrated in the present spinning method over the conventional spinning method. Furthermore, the yarn diameter is decreased and thereby the yarn density is increased. There is also a 10% to 30% increase in the fuzz. The rollability of a fiber bundle that includes a mix of polyester and viscose rayon as raw materials is enhanced by 40 m/min. That is, a 10% increase in the rollability can be demonstrated in the present spinning method over the conventional spinning method. Furthermore, the yarn diameter is decreased and thereby the yarn density is increased. There is also a 10% to 30% increase in the fuzz. The reliability of a fiber bundle that includes a mix of polyester and cotton as raw materials is enhanced by 40 m/min. That is, a 10% increase in the rollability can be demonstrated in the present spinning method over the conventional spinning method. Furthermore, the yarn diameter is decreased and thereby the yarn density is increased. There is also a 10% to 40% increase in the fuzz. The rollability of a fiber bundle that includes acrylic fibers and acrylic-based fibers as raw materials is enhanced by 40 m/min. That is, a 10% increase in the rollability can be demonstrated in the present spinning method over the conventional spinning method. Furthermore, the yarn diameter is decreased and thereby the yarn density is increased. There is also a 10% increase in the fuzz. It is therefore convincingly demonstrated that the quality of the spun yarn Y is enhanced if the fiber bundle S includes the above raw materials.

[0050] The present invention is not limited to the above embodiments. In the above embodiment, an example is presented in which the type of raw material of the fiber bundle S is input through the touch panel display 102, and the main controller 100 controls the mixing quantity of the agent in the agent supplying device 50 based on the input raw material. Alternatively, a fixed mixing quantity of the agent can be used regardless of the raw material of the fiber bundle S. The agent can also be changed to suit the raw material of the fiber bundle S. In this case, the agent used can differ in composition and/or viscosity, and the like, to suit the raw material.

[0051] According to a different aspect of the present invention, the spinning method for forming the spun yarn Y by twisting the fiber bundle S by the action of the swirling current of the air includes the agent mixing step at which the agent is mixed with the air and the spinning step at which the fiber bundle is twisted by the agent-containing air, and in which the fiber bundle includes at least one raw material having a lower Young's modulus than that of polyester. Young's modulus is a ratio between stress and strain of a material exhibiting elastic behavior. In FIG. 6, the slope of the straight part of each of the tenacity-elongation curves of different raw materials represents Young's modulus of that raw material. In the straight part, the elongation degree (%) is in the range from 0% to 5%.

[0052] FIG. 6 is a graph for explaining the tenacity-elongation curves in which the horizontal axis represents the elongation degree (%) and the vertical axis represents the tenacity (gf/d). As shown in FIG. 6, wool, acetate, rayon, acrylic, nylon, and the like are raw materials having a lower Young's modulus than that of polyester. On the tenacity-elongation curve, these raw materials have a small-value portion of tenacity relative to the elongation as compared to polyester. When a fiber bundle S made of such a raw material is subjected to air-jet spinning by the action of the agent-containing air, the friction resistance between the fibers increases, leading to an increased convergence between the fibers. Consequently, the fibers are brought together tightly, resulting in a reduced diameter of the spun yarn Y. Furthermore, the friction resistance between the fiber bundle S and the hollow guide shaft 72 of the air-jet spinning device 7 is reduced due to the presence of the agent. Consequently, the trailing fiber ends of the fiber bundle S ride the air current and are whirled at a high speed, leading to more fibers being wound on the outer side of the fiber bundle S and more fuzz. Hence, the quality of the spun yarn Y being formed can be enhanced by this spinning method.

[0053] In the above embodiment, the air-jet spinning device 7 that includes the fiber guide 71, the hollow guide shaft 72, and the nozzle block 73 is presented as an example; however, the structure of the air-jet spinning device is not limited to this. Moreover, the air-jet spinning device can include a pair of air-jet nozzles that twist the fiber bundle in opposite directions. The spinning machine can be an open-ended spinning machine.

[0054] In the above embodiment, the spinning machine 1 includes one unit of the air distributing device 40 and one unit of the agent supplying device 50 corresponding to all of the spinning units 2. Alternatively, one unit of the air distributing device and one unit of the agent supplying device can be arranged corresponding to each of the spinning units 2. Alternatively, one unit of the air distributing device and one unit of the agent supplying device can be arranged corresponding to each group of spinning units consisting of one or more spinning units among all of the spinning units 2.

[0055] An earnest research conducted by the inventors of the present invention to realize the above object has led to the findings that the quality of the yarn can be enhanced by mixing an agent with air when twisting a fiber bundle composed of a specific raw material to form a yarn by the action of a swirling current of the air.

[0056] A spinning method according to an aspect of the present invention is a method for forming a yarn by twisting a fiber bundle by the action of a swirling current of air, and includes mixing and spinning. The mixing includes mixing an agent with the air. The spinning includes twisting the fiber bundle by the action of the agent-containing air. The fiber bundle includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers.

[0057] In the above spinning method, the fiber bundle includes as a raw material at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers. When the fiber bundle that includes the above raw materials is subjected to air-jet spinning by the action of the agent-containing air, the friction resistance between the fibers is increased due to the presence of the agent, leading to an increased convergence between the fibers. Consequently, the fibers are brought together tightly, resulting in a reduced diameter of the spun yarn. Furthermore, the friction resistance between the fiber bundle and the air-jet spinning device (hollow guide shaft) is reduced due to the presence of the agent. Consequently, the fiber bundle rides the air current and the trailing fiber ends of the fiber bundle are whirled at a high speed, resulting in more fibers being wound on the outer side of the fiber bundle and more fuzz. Hence, the quality of the yarn being formed by this spinning method can be enhanced.

[0058] With this spinning method, the yarn having a small diameter (a tightly twisted yarn), that is, a yarn that is strong against squeezing, is formed. Consequently, a yarn having a predetermined tenacity can be formed even if a spinning speed is increased. Hence, a productivity of the yarn can be enhanced with this spinning method.

[0059] According to another aspect of the present invention, the spinning includes removing stains on a device that twists the fiber bundle. By this action, for example, deposition of any oily substance present in the fiber bundle on the device can be suppressed. Consequently, the phenomenon of the trailing fiber ends of the fiber bundle not being sufficiently whirled due to the deposited oily substance can be avoided when the fiber bundle is being twisted by the action of the swirling current of the air. As a result, formation of a weak yarn having a low tenacity can be prevented. Furthermore, processability can be enhanced because a device operator is freed from the task of removing the deposited oily substance.

[0060] According to still another aspect of the present invention, the spinning includes forming fuzz in the yarn. By doing so, the feel and appearance of the yarn can be enhanced.

[0061] According to still another aspect of the present invention, wherein the spinning includes forming the yarn at a rate ranging from 300 m/min to 600 m/min. At this rate of yarn formation, the quality of the yarn can be ensured and the productivity of the yarn can be enhanced.

[0062] According to still another aspect of the present invention, the agent can be a lubricant. By using a lubricant as the agent, the friction resistance between the fibers in the fiber bundle can be increased and the friction resistance between the air-jet spinning device and the fiber bundle can be reduced.

[0063] A spinning machine according to still another aspect of the present invention forms the yarn from the fiber bundle that includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers, and includes a drafting device, an air-jet spinning device, an agent supplying device, and a winding device. The drafting device drafts the fiber bundle. The air-jet spinning device twists the fiber bundle drafted by the drafting device by the action of the swirling current of the air and forms the yarn. The agent supplying device mixes the agent with the air. The winding device winds the yarn formed by the air-jet spinning device.

[0064] In this spinning machine, the agent is mixed with the air that twists the fiber bundle including at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers. When the fiber bundle that includes the above raw materials is subjected to air-jet spinning by the action of the agent-containing air, the friction resistance between the fibers is increased due to the presence of the agent, leading to an increased convergence between the fibers. Consequently, the fibers are brought together tightly, resulting in a reduced diameter of the spun yarn. Furthermore, the friction resistance between the fiber bundle and the air-jet spinning device (hollow guide shaft) is reduced due to the presence of the agent. Consequently, the fiber bundle rides the air current and the trailing fiber ends of the fiber bundle are whirled at a high speed, resulting in more fibers being wound on the outer side of the fiber bundle and more fuzz. Hence, the quality of the yarn being formed with this spinning machine can be enhanced.

[0065] According to still another aspect of the present invention, the spinning machine can include an input unit and a control unit. The input unit allows input of a type of raw material of the fiber bundle. The control unit controls a mixing quantity of the agent to be mixed with the air by the agent supplying device based on the type of raw material input with the input unit. With this structure, a quantity of the agent that is suited to the raw material can be mixed.

[0066] According to still another aspect of the present invention, the air-jet spinning device can include a spinning nozzle member, a fiber guiding member, and a hollow guide shaft. The spinning nozzle member constitutes a spinning chamber into which the fiber bundle is guided and twisted, and has an air hole through which the air is guided into the spinning chamber. The fiber guiding member guides the fiber bundle drafted by the drafting device into the spinning chamber. The hollow guide shaft guides the fiber bundle twisted in the spinning chamber. In the air-jet spinning device that includes the hollow guide shaft, by mixing the agent in the air, the friction resistance between the hollow guide shaft and the fiber bundle can be reduced.

[0067] According to still another aspect of the present invention, the agent supplying device can include a storage unit and a spraying unit. The storage unit stores therein the agent. The spraying unit sprays the agent stored in the storage unit. By spraying the agent, the agent can be mixed with the air in the form of mist, and thereby the agent can be uniformly mixed with the air.

[0068] A yarn according to still another aspect of the present invention is formed by the above spinning method. Hence, the yarn that is formed is of a small diameter and has more fuzz, and hence is of an enhanced quality.

[0069] A spinning method according to still another aspect of the present invention forms the yarn by twisting the fiber bundle by the action of the swirling current of air, and includes mixing and spinning. The mixing includes mixing an agent with the air. The spinning includes twisting the fiber bundle by the action of the agent-containing air. The fiber bundle includes at least one raw material having a lower Young's modulus than that of polyester. Young's modulus is a ratio between stress and strain of a material exhibiting elastic behavior. The slope of the straight part of the tenacity-elongation curve represents Young's modulus. In the straight part, the elongation degree (%) is in the range from 0% to 5%.

[0070] In the above spinning method, the fiber bundle includes at least one raw material having a lower Young's modulus than that of polyester on the tenacity-elongation curve. When the fiber bundle that includes the above raw material is subjected to air-jet spinning by the action of the agent-containing air, the friction resistance between the fibers is increased sue to the presence of the agent, leading to an increased convergence between the fibers. Consequently, the fibers are brought together tightly, resulting in a reduced diameter of the spun yarn. Furthermore, the friction resistance between the trailing fiber ends of the fiber bundle and the air-jet spinning device (hollow guide shaft) is reduced due to the presence of the agent. Consequently, the trailing fiber ends of the fiber bundle ride the air current and are whirled at a high speed, resulting in more fibers being wound on the outer side of the fiber bundle and more fuzz. Hence, the quality of the yarn being formed by this spinning method can be enhanced.

[0071] According to another aspect of the present invention, the natural fibers do not include cotton.

[0072] According to still another aspect of the present invention, the natural fibers include flax.

[0073] Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching of the claims.

Claims

1. A spinning method for forming a yarn (Y) by twisting a fiber bundle (S) by the action of a swirling current of air, the spinning method comprising:

mixing an agent with the air; and

spinning including twisting the fiber bundle (S) by the action of the agent-containing air,

wherein the fiber bundle (S) includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, polyacrylonitrile-based fibers.

2. The spinning method as claimed in Claim 1, wherein the natural fibers do not include cotton or include flax.

3. The spinning method as claimed in any one of Claims 1 and 2, wherein the spinning includes removing stains on a device that twists the fiber bundle (S).

4. The spinning method as claimed in any one of Claims 1 to 3, wherein the agent is a lubricant.

5. A spinning machine configured to form a yarn (Y) from a fiber bundle (S) that includes at least one of natural fibers, regenerated fibers, semi-synthetic fibers, polyamide-based fibers, and polyacrylonitrile-based fibers, the spinning machine comprising:

a drafting device (6) configured to draft the fiber bundle (S);

an air-jet spinning device (7) configured to twist the fiber bundle (S) drafted by the drafting device (6) by the action of a swirling current of air and to form the yarn (Y);

an agent supplying device (50) configured to mix an agent with the air; and

a winding device (12) configured to wind the yarn (Y) formed by the air-jet spinning device (7).

6. The spinning machine as claimed in Claim 5, further comprising:

an input unit (102) configured to allow input of a type of raw material of the fiber bundle (S); and

a control unit (100) configured to control a mixing quantity of the agent to be mixed with the air by the agent supplying device (50) based on the type of raw material input with the input unit (102).

7. The spinning machine as claimed in Claim 6, wherein the input unit (102) is configured to allow a device operator to select the type of raw material from among plural types displayed on a display screen, or wherein the input unit (102) is configured to allow the device operator to directly input the type of raw material with a keyboard.

8. The spinning machine as claimed in any one of Claims 5 to 7, further comprising:

plural spinning units (2) arranged side by side; and

an air distributing device (40) configured to supply the air to the air-jet spinning device (7),

wherein the air distributing device (40) includes
a first air pipe (42) that extends parallel to an arrangement direction of the spinning units (2), and
a first distribution pipe (43) configured to diverge and guide the air flowing in the first air pipe (42) to the air-jet spinning device (7), and includes an air quantity adjusting device (43a).

9. The spinning machine as claimed in Claim 8, wherein the air distributing device (40) includes
a second air pipe (44) that extends parallel to the arrangement direction of the spinning units (2), and
a second distribution pipe (45) configured to diverge and guide the air flowing through the second air pipe (44) to the air-jet spinning device (7), and includes an air quantity adjusting device (45a).

10. The spinning machine as claimed in any one of Claims 5 to 7, further comprising:

plural spinning units (2) arranged side by side; and

an air distributing device (40) configured to supply the air to the air-jet spinning device (7),

wherein one unit of the agent supplying device (50) and one unit of the air distributing device (40) are arranged corresponding to the plural spinning units (2).

11. The spinning machine as claimed in any one of Claims 5 to 7, further comprising:

plural spinning units (2) arranged side by side; and

an air distributing device (40) configured to supply the air to the air-jet spinning device (7),

wherein one unit of the agent supplying device (50) and one unit of the air distributing device (40) are arranged corresponding to each spinning unit (2) among the plural spinning units (2).

12. The spinning machine as claimed in any one of Claims 5 to 7, further comprising:

plural spinning units (2) arranged side by side; and

an air distributing device (40) configured to supply the air to the air-jet spinning device (7),

wherein one unit of the agent supplying device (50) and one unit of the air distributing device (40) are arranged corresponding to each group of spinning units (2) consisting of one or more spinning units (2) among the plural spinning units (2).

13. The spinning machine as claimed in any one of Claims 5 to 12, wherein the air-jet spinning device (7) includes:

a spinning nozzle member (73) that constitutes a spinning chamber (SC) into which the fiber bundle (S) is guided and twisted, and that has an air hole (73a) through which the air is guided into the spinning chamber (SC);

a fiber guiding member (71) configured to guide the fiber bundle (S) drafted by the drafting device (6) into the spinning chamber (SC); and

a hollow guide shaft (72) configured to guide the fiber bundle (S) that has been twisted inside the spinning chamber (SC).

14. The spinning machine as claimed in any one of Claims 5 to 13, wherein the agent supplying device (50) includes
a storage unit (53) configured to store therein the agent; and
a spraying unit (54) configured to spray the agent stored in a storage unit (53).

15. A spinning method for forming a yarn (Y) by twisting a fiber bundle (S) by the action of a swirling current of air, the spinning method comprising:

mixing an agent with the air; and

spinning including twisting the fiber bundle (S) by the action of the agent-containing air,

wherein the fiber bundle (S) includes at least one raw material having a lower Young's modulus than that of polyester.

16. The spinning method as claimed in Claim 15, wherein the at least one raw material comprises natural fibers, wherein the natural fibers do not include cotton or include flax.

Drawing