Fire retardant compositions and methods and apparatuses for making the same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
D01H-004/00
B32B-005/26
B32B-005/02
D02G-001/02
D04H-001/42
출원번호
US-0399748
(2012-02-17)
등록번호
US-8850784
(2014-10-07)
발명자
/ 주소
Ke, Tung-Yuan
출원인 / 주소
Lorica International Corporation
대리인 / 주소
Potts, Jerry R.
인용정보
피인용 횟수 :
1인용 특허 :
44
초록▼
An apparatus for producing a textile product generally includes a feeding section for providing a starting material to facilitate producing a textile product derived from the starting material; a drafting section operably coupled to the feeding section for gripping, pulling, stretching and breaking
An apparatus for producing a textile product generally includes a feeding section for providing a starting material to facilitate producing a textile product derived from the starting material; a drafting section operably coupled to the feeding section for gripping, pulling, stretching and breaking at least one strand of the starting material into at least one continuous and cohesive network of an intermediate product; and a spinning section operably coupled to the drafting section for winding and twisting the at least one continuous and cohesive network of an intermediate product onto a removable receiving member to form the textile product; the feeding section, the drafting section, and the spinning section are configured to form the textile product in a continuous operation.
대표청구항▼
1. An apparatus for converting at least one tow of filaments into a twisted yarn comprising: a feeding section configured to support and feed the at least one tow of filaments;wherein said at least one tow of filaments is a tow of continuous filaments being longitudinally aligned with one another in
1. An apparatus for converting at least one tow of filaments into a twisted yarn comprising: a feeding section configured to support and feed the at least one tow of filaments;wherein said at least one tow of filaments is a tow of continuous filaments being longitudinally aligned with one another in a generally flat and untwisted form;a drafting section operably coupled to the feeding section, the drafting section comprising;a first pair of rollers having substantially conterminous opposed surfaces rotating at a first speed, said first pair of rollers being configured to receive, transport and grip the filaments from the feeding section;a second pair of rollers being downstream and having substantially conterminous opposed surfaces rotating at a second faster speed configured to receive, transport and grip broken fibers from the first pair of rollers;the first and second pairs of rollers configured to exert a sufficient gripping force upon the filaments and configured to rotate at relative speeds so as to stretch and break the filaments thereby forming a cohesive elongated network of fibers therebetween; andwherein the rotational speed of the downstream pair of rollers is from about 1.25 times to about 100 times the rotational speed of the upstream pair of rollers;a spinning section operably coupled to the drafting section, the spinning section configured to spin and twist the cohesive elongated network of fibers onto a yarn body to form a twisted yarn; andwherein the feeding section, the drafting section and the spinning section being configured in a single pass operation to convert the tow of continuous filaments into twisted yarn. 2. The apparatus of claim 1 wherein said feeding section includes at least one spool of continuous filaments removably mounted thereon. 3. The apparatus of claim 2 wherein the filaments have a composition selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO), polybenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlone), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneema®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide, protein, milk casein, stainless steel, nickel, other metals and metal alloys. 4. The apparatus of claim 3, wherein the filaments have a twist count in the range of about 0 twists per meter and about 100 twists per meter. 5. The apparatus of claim 1 wherein the feeding section is configured to support and feed two separate tows of filaments. 6. The apparatus of claim 5 wherein the drafting section is configured to stretch and break and to form a single elongated network of fibers from the two separate tows of filaments. 7. The apparatus of claim 5 wherein the drafting section is configured to stretch and break and to form two separate elongated networks of fibers from the two separate tows of filaments. 8. The apparatus of claim 7 wherein the spinning section is configured to form a twisted yarn body by spinning and twisting the two separate elongated networks of fibers to form one twisted strand of yarn. 9. The apparatus of claim 1 wherein the feeding section is configured to support and said at least one tow of filaments and at least a strand of yarn. 10. The apparatus of claim 9 wherein the spinning section is configured to form a twisted yarn body by spinning and twisting the elongated network of fibers and the yarn to form one twisted strand of yarn. 11. The apparatus of claim 1 wherein the first pair of rollers is spaced between 50 mm and 500 mm from the second pair of rollers. 12. An apparatus for converting a supply of filaments into a twisted yarn comprising: a feeding component configured to support and feed the supply of filaments:a drafting component coupled to the feeding section, the drafting section comprising:a first pair of rollers configured to receive and grip the filaments from the feeding section;a second pair of rollers spaced between 50 mm and 1000 mm from the first pair of rollers and configured to receive and to grip an elongated network of fibers from the first pair of rollers; andthe first and second pairs of rollers each exerting a gripping force and configured to rotate at relative speeds so as to stretch and break the filaments thereby forming the elongated network of fibers therebetween; andwherein the rotational speed of the downstream pair of rollers is from about 1.25 times to about 100 times the rotational speed of the upstream pair of rollers;a spinning component coupled to the drafting section so as to receive the elongated network of fibers and configured to spin and twist the network of fibers to form the twisted yarn;the feeding component, the drafting component and the spinning component are integrated into a single unit configured to convert the filaments into a twisted yarn in a continuous operation. 13. The apparatus of claim 12 wherein the supply of filaments have a composition selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO), polvbenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlon®), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneerria®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide, protein, milk casein, stainless steel, nickel, other metals and metal alloys. 14. The apparatus of claim 12 further comprising a pressurizing element configured to provide the gripping force. 15. The apparatus of claim 14 wherein the pressurizing element includes a first pressurizing element configured to urge the first set of rollers together and a second pressurizing element configured to urge the second set of rollers together. 16. The apparatus of claim 12 wherein the drafting section includes a third pair of rollers configured to at least transport material between the first pair of rollers and the second pair of rollers. 17. The apparatus of claim 12 further comprising a third pair of rollers configured to at least transport material between the second pair of rollers and the spinning section. 18. The apparatus of claim 12 wherein the spinning component is configured to provide a twist count in the range of 100 to 2000 twists per meter. 19. The apparatus of claim 12 wherein the spinning section is configured to be equipped with a compact spinning device. 20. The apparatus of claim 12 wherein the spinning section is configured to be equipped with a pot spinning device. 21. The apparatus of claim of claim 16, wherein said third pair of rollers includes an upper roller and a lower roller, said upper roller and said lower roller being equipped with belts which flank and transport stretched and broken elongate network of fibers between the third pair of rollers and the second pair of rollers. 22. The apparatus of claim 1, wherein said spinning section is configured to be equipped with a pot spinning device; and wherein said yarn body is a yarn cake. 23. The apparatus of claim 1, wherein said spinning section is configured to be equipped with a ring-spinning device; and wherein said yam body is a yarn bobbin. 24. An apparatus for producing a yarn product, comprising: a feeding section for providing a starting material to facilitate producing a yarn product derived from said starting material;a drafting section operably coupled to said feeding section for gripping, pulling, stretching and breaking at least one strand of said starting material into at least one continuous and cohesive network of an intermediate product;wherein said drafting section operates at a draft ratio which is in a range of about 1.25 to about 100;a spinning section operably coupled to said drafting section for winding and twisting said at least one continuous and cohesive network of an intermediate product onto a removable receiving member to form the yarn product; andwherein the feeding section, the drafting section and the spinning section are configured to form the yarn product in a continuous single bass operation. 25. The apparatus according to claim 24, wherein said starting material is a filamentous starting material. 26. The apparatus according to claim 24, wherein said starting material is a fibrous starting material. 27. The apparatus according to claim 24, wherein said feeding section includes a plurality of feeding elements for providing a plurality of starting materials to facilitate producing a yarn product consisting of a blended form of the plurality of starting materials. 28. The apparatus for according to claim 27, wherein said starting materials includes at least one filamentous starting material. 29. The apparatus according to claim 28, wherein said plurality of starting materials further includes at least one fibrous starting material. 30. The apparatus according to claim 25, wherein said filamentous starting material is selected from a group of filamentous starting materials consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid fibers, para-aramid fibers, meta-aramid fibers including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®; polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO) fiber, polybenzimidazole (PBI), polyamide imide, KERMEL® fiber, Melamine (BASOFIL®) fiber, polyimide (P84) fiber, polysulfonamide (Tanlon®) fiber, polyamide fiber, fluoro fiber, polyester-polyarylate (Vectran®) fiber, polybutylene terephthalate (PBT) fiber, polyethylene (Dyneema®) fiber, pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5) fiber, viscose rayon, Lyocell® fibers, FR rayon, nylon fibers, polyester fibers, acrylic fibers, PAN fibers, modacrylic fiber, chlorofiber (Rhovyl®) fiber, polyvinyl halide fiber, protein fiber, and milk casein fiber, stainless steel fiber, nickel fiber, metal fiber and metal alloy fibers. 31. The apparatus according to claim 26, wherein said one fibrous material is selected from a group of fibrous materials consisting of carbon fibers, ceramic fibers, glass fibers, metal fibers, carbonaceous fibers, inorganic fibers, acrylic fibers, tetrafluoroethylene fibers, polyamide fibers, vinyl fibers, protein fibers, blended fibers and oxide fibers derived from boron, thoria and zirconia. 32. The apparatus according to claim 31, wherein said blended fibers are selected from a group of blended fibers consisting of carbon-based PAN and viscose rayon, carbon-based PAN and stainless steel, carbon-based PAN and an aramid material, and stainless steel and an aramid material. 33. The apparatus according to claim 31, wherein said carbonaceous fibers are selected from a group of carbonaceous fibers consisting of cotton fibers, wool fibers, polyester fibers, polyolefin fibers, nylon, viscose rayon and novoloid phenolic. 34. The apparatus according to claim 31, wherein said inorganic fibers is selected from a group of inorganic fibers consisting of silica, silica alumina, potassium, titanate, silicon carbide, silicon nitride, boron nitride and boron. 35. An apparatus for producing a yarn product, comprising: a feeding section for forming a plurality of tows from a plurality of feeding materials;a drafting section operably coupled to said feeding section for gripping, pulling, stretching and breaking said plurality of tows to convert them into a plurality of individual ones of continuous fibrous networks, wherein each individual fibrous network is formed of a plurality of wavy fibers;wherein said drafting section operates at a draft ratio which is in a range of about 1.25 to about 100;a spinning section operably coupled to said drafting section for winding and twisting said plurality of individual ones of continuous fibrous networks onto a removable yarn body to form the yarn product; andwherein said plurality of feeding materials is selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO), polybenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlon®), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneema®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide. 36. The apparatus for producing a yarn product according to claim 35, wherein said plurality of tows includes at least a tow of filaments and at least another tow of filaments. 37. The apparatus for producing a yarn product according to claim 35, wherein said plurality of tows includes at least a tow of filaments and at least a tow of rovings. 38. The apparatus for producing a yarn product according to claim 36, wherein said yarn product is either pure yarn or blended yarn. 39. The apparatus for producing a yarn product according to claim 37, wherein said yarn product is either pure yarn or blended yarn. 40. The apparatus for producing a yarn product according to claim 35, wherein said drafting section is configured for alternately gripping and pulling at least one individual one of said plurality of tows without stretching and breaking it to provide at least one non truncated tow; and wherein said spinning section is configured for winding and twisting said plurality of individual ones of continuous fibrous networks with said at least one non truncated tow onto a removable yarn body to form the yarn product. 41. The apparatus for producing a yarn product according to claim 40, wherein said plurality of tows includes at least a tow of filaments and at least a tow of yam. 42. The apparatus for producing a yarn product according to claim 40, wherein said plurality of tows includes at least a tow of filaments and a tow of rovings. 43. The apparatus for producing a yarn product according to claim 40, wherein said one non truncated tow is a tow of yarn. 44. The apparatus for producing a yarn product according to claim 40, wherein said yarn product is twisted yarn. 45. The apparatus for producing a yarn product according to claim 35, wherein the feeding section, the drafting section and the spinning section are configured to form the yarn product in a continuous operation. 46. An apparatus for producing twisted yarn, comprising: a feeding component for forming a tow from a starting material and for forming another tow from another starting material;a drafting component for forming a first network of fibers from said tow as it travels along a stretching and breaking path of travel and for forming a second network of fibers from said another tow as it travels along another stretching and breaking path of travel; andwherein said drafting section operates at a draft ratio which is in a range of about 1.25 to about 100;a spinning component for twisting said first network of fibers and said second network of fibers together to form the twisted yarn. 47. The apparatus for producing twisted yarn according to claim 46, wherein said stretching and breaking path of travel and said another stretching and breaking path of travel are the same path of travel to facilitate forming a single elongated network of fibers. 48. The apparatus for producing twisted yarn according to claim 46, wherein said stretching and breaking path of travel and said another stretching and breaking path of travel are different paths of travel to facilitate forming two separate elongated network of fibers. 49. The apparatus for producing twisted yarn according to claim 46, wherein said stretching and breaking path of travel includes a path of travel between an upstream first pair of rollers and a downstream second pair of rollers; wherein said upstream first pair of rollers and said downstream second pair of rollers are operating at different rotational speeds to facilitate stretching and breaking said tow as it travels along said stretching and breaking path of travel; andwherein said tow is a tow of filaments having a composition selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO), polybenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlon®), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneema®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide, protein, milk casein, stainless steel, nickel, other metals and metal alloys. 50. The apparatus for producing twisted yarn according to claim 49, wherein said another stretching and breaking path of travel includes a path of travel between an upstream third pair of rollers and a downstream fourth pair of rollers; wherein said upstream third pair of rollers and said downstream fourth pair of rollers are operating at different rotational speeds to facilitate stretching and breaking said another tow as it travels along said another stretching and breaking path of travel; andwherein said another tow is another tow of filaments having a composition selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polyparaphenylene benzo-bis-oxazol (PBO), polybenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlon®), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneema®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide, protein, milk casein, stainless steel, nickel, other metals and metal alloys. 51. The apparatus for producing twisted yarn according to claim 49 wherein said upstream first pair of rollers and said downstream second pair of rollers are spaced apart from one another by about 50 mm to about 500 mm. 52. The apparatus for producing twisted yarn according to claim 49 wherein said upstream first pair of rollers and said downstream second pair of rollers are spaced apart from one another by about 50 mm to about 240 mm. 53. The apparatus for producing twisted yarn according to claim 49, wherein the rotational speed of the downstream second pair of rollers is from 1.25 times to 100 times the rotational speed of the upstream first pair of rollers. 54. The apparatus for producing twisted yarn according to claim 50, wherein the rotational speed of the downstream fourth pair of rollers is from about 1.25 times to about 100 times the rotational speed of the upstream third pair of rollers. 55. The apparatus for producing twisted yarn according to claim 46, wherein the spinning component is configured to provide a twist count in the range of 100 to 2000 twists per meter. 56. The apparatus for producing twisted yarn according to claim 46, wherein the spinning component is configured to be equipped with a compact spinning device. 57. The apparatus for producing twisted yarn according to claim 46, wherein the spinning component is configured to be equipped with a pot spinning device. 58. The apparatus for producing twisted yarn according to claim 46, wherein said tow is a tow of filaments and wherein said another tow is another tow of filaments. 59. The apparatus for producing twisted yarn according to claim 46, wherein the feeding component, the drafting component and the spinning component are integrated into a single unit configured to convert the filaments into a twisted yarn in a continuous operation. 60. The apparatus of claim 24, wherein the yarn product is a product for fire-resistant clothing, including: fire-resistant underwear, a fire-resistant jacket; a fire-resistant pants, firefighter pants, firefighter undergarments. 61. An apparatus for producing an intermediate for the production of goods, comprising: a feeding component having at least one feeding element for providing a drafting component with at least one continuous precursor feeding material in a substantially flat, minimally twisted state;wherein said drafting component has a least one drafting element for converting said at least one continuous precursor feeding material into a continuous mass of a randomly arranged collection of minimally twisted wool-like structures;wherein said drafting element operates at a draft ratio which is in a range of about 1.25 to about 100;wherein said feeding component and said drafting component are integrated into a single unit for continuous operation; andwherein said at least one continuous precursor feeding material is selected from a group consisting of PAN, oxidized PAN, carbonized PAN, carbon-based fiber, aramid, para-aramid, meta-aramid including Kevlar®, Twaron®, Technora®, Heracron®, Nomex®, New Star®, polyphenylene sulfide (PPS), polyether-ether ketone (PEEK), phenolic (NOVOLOID®), polvparaphenylene benzo-bis-oxazol (PBO), polybenzimidazole (PBI), polyamide imide, KERMEL®, Melamine (BASOFIL®), polyimide (P84), polysulfonamide (Tanlon®), polyamide, fluoro, polyester-polyarylate (Vectran®), polybutylene terephthalate (PBT), polyethylene (Dyneema®), pyridinylene-1, 4 (2,5-dihydroxy) phenylene (M5), viscose rayon, Lyocell®, FR rayon, nylon, polyester, acrylic, modacrylic, chlorofiber (Rhovyl®), polyvinyl halide. 62. The apparatus according to claim 61, wherein said feeding component is adapted to receive at least one spool of a starting material for delivery to said at least one feeding element; and wherein said feeding component provides a passive process for maintaining the feeding material in said substantially flat configuration, with a minimum twist that is no more than about double the twist of the starting material. 63. The apparatus according to claim 62, further comprising: a spinning component coupled to said drafting component for transforming said continuous mass of wool-like structures into a yarn by winding and twisting said continuous mass of wool-like structures onto a receiving member. 64. The apparatus according to claim 63, wherein said feeding component, said drafting component and said spinning component are integrated into a single unit for providing a continuous operation. 65. The apparatus according to claim 63, wherein the spinning component is configured to provide a yarn having a twist count in the range of 100 to 2000 twists per meter. 66. The apparatus according to claim 62, wherein said feeding component includes at least two feeding elements for providing at least two types of feeding materials in a substantially flat, minimally twisted state. 67. The apparatus according to claim 66, wherein said drafting component has at least two drafting elements. 68. The apparatus according to claim 67, wherein each individual one of said at least two drafting elements comprises a pair of upstream rollers having a first rotational speed and a pair of downstream rollers having a second rotational speed; wherein one of said at least two drafting elements defines a stretching and breaking path that extends between an associated pair of upstream rollers and an associated pair of downstream rollers; andwherein the second rotational speed of the associated pair of downstream rollers is faster that the first rotational speed of the associated pair of upstream rollers to facilitate the stretching and breaking of the feeding material as it travels along said stretching and breaking path. 69. The apparatus according to claim 68, wherein said pair of upstream rollers is spaced between about 50 mm and about 500 mm from said pair of downstream rollers. 70. The apparatus according to claim 68, wherein said pair of upstream rollers is spaced between about 50 mm and about 240 mm from said downstream rollers. 71. The apparatus according to claim 68, wherein the rotational speed of the downstream pair of rollers is from about 1.25 times to about 100 times the rotational speed of the upstream pair of rollers. 72. The apparatus according to claim 68, wherein another one of said at least two drafting elements defines a non stretching and non breaking path that extends between another associated pair of upstream rollers and another associated pair of downstream rollers; and wherein the second rotational speed of the another associate pair of downstream rollers is substantially the same as the first rotational speed of the another associated pair of upstream rollers to substantially prevent the stretching and breaking of the feed material as it travels along said non stretching and non breaking path.
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