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In the texturing processes, a continuous filament yarn has to undergo a major change in its physical form, by
becoming crimped, coiled or looped along its lengths. . Only multifilament continuous filament yarns are
suitable for texturing. There are various methods that may be used to produce textured continuous filament
yarns. Most are only applicable to thermoplastic continuous filament yarns as they involve heating the
filaments while effecting the textured profile, then cooling to retain it in the filaments. From the technical
perspective, the ones most commonly referred to are
Knife Edge: where the Filament yarn is heated and pulled across a knife at an acute angle. When the
yarn is cooled and released it retains a spring or curled ribbon appearance, i.e. the profile is heat-set.
Stuffer Box: here the filaments pass through a heated box, but are fed into it faster than their removal
rate i.e. an overfeed. This forces them to adopt a random wavy crimped pattern while heated; subsequent
cooling sets their textured form.
Air Jet: with this method overfeeding of filaments at high speed into a chamber is also employed, but
instead of using heat to facilitate the texture profile, compressed air is blown into the chamber and this
causes the loose lengths of the filaments in the yarn to spread apart and form entangled random loops. The
entanglement retains the texture of random loops
False twist: in this method the continuous filament yarns are twisted and heated simultaneously, and
then untwisted when cold, thereby loosely retaining the heat-set helical shape of the twist.
Knit-De-Knit: here Filament yarns are knitted into a narrow diameter tube and heat-set (i.e. heated
and then cooled). The yarns are then de-knitted, giving them a wavy configuration.
Bicomponent Process: with this method the texture is obtained by twisting to together filaments of
high and low potential shrinkage. Subjecting the resulting yarn to washing or steaming results in the
differential shrinkage of the filaments to form the bulked profile.
False-twist Texturing
Principle and process
Filament yarns like polyester and nylon and thermoplastic. They soften and can be easily deformed with the
application of heat; and upon cooling; the filaments remain in their deformed state (i.e. the filaments become
heat-set). Normally if filaments are twisted, torsional stress develops in the filaments and the filaments will
want to untwist to release the stress. However, if such filaments are twisted and heat-set (i.e. heated above
their glass transition temperature and then cooled below their glass transition temperature), their torsional
stress will be relaxed and the filaments will remain twisted even though the external force is removed. If
these filaments are then untwisted, stress will develop again in the individual filaments. If these stressed
filaments are allowed to relax, they will seek the minimum-energy-state (or least stressed state!) by
forming adjacent helices and snarls. These helices and snarls prevent the individual filaments from staying
as closely packed as before and the filaments will occupy a much greater volume than before. In other
words, the filaments become bulky and textured. This process is illustrated in Figure.1
Flat
filaments
Textured
filaments
HEAT
SET
TWIST
Stress
free
Under
stress
UNTWIST
Stress
relaxed
Stressed
again
RELAX
Stress
relaxed
Figure 2: Traditional filament yarn texturing with separate twisting, heat-setting, and untwisting stages
In principle, continuous false-twist (FT) texturing is very similar to a dynamic false-twisting process, as
indicated in figure 3. The main difference is that in FT texturing, heating setting is involved. This is also
why FT texturing can only work on thermoplastic filaments. Non-thermoplastic filaments, such as glass
filaments, can not be false-twist textured.
F.T.
Cool
Heat
Stationary
false-twisting
Dynamic
false-twisting
Cool
Heat
False-twist
texturing
Fig. 3: Difference between stationary false twisting, dynamic false twisting, and false-twist texturing
A typical false-twist texturing process is shown in Figure 4.
Cooling zone
Twisti ng
device
First
heater
Second
heater
(if required)
Supply
yarn
Textured
yarn
The machines, which use such system, are the so-called 1st generation machines.
A hollow tube, inside which a pin is fixed crosswise, forms the twisting device; the yarn is wound around
this pin with a full rotate on of 360.
AIR-JET TEXTURING
Principle and process
Air-jet texturing is a versatile process. It works with both thermo-plastic (eg. Polyester and nylon) and nonthermoplastic (e.g. rayon, glass filament) filaments. In air-jet texturing, yarn morphology is modified without
disturbing the internal structure of individual filaments. This is achieved by creating loops and air pockets in
the yarn by opening up the yarn structure, buckling the filaments, and locking up the structure again.
The principle of loop formation in air jet texturing can be described as:
Overfeed the filament yarn into an air nozzle
Open the feed yarn (or parent yarn) in a turbulent air stream
The air stream displaces the filaments, and convert the excess length into loops
interlace filaments to stabilise the loop structure
Supply ya rn
Com press ed air in
Wetting
Turbulence
Overfeeding
Air jet
The process can be considered as mechanical if the air jet is cold; the textured yarn obtained through a
simple aerodynamic stress presents structural characteristics which are considerably different from those of a
false-twist yarn (higher bulkiness, lower elasticity, similarity to traditional yarns).
Wetting of the filaments before the air nozzle is used for the following reasons:
VERY IMPORTANT
Twist-texturizing (including false twist): A filament yarn which has been twisted under the
influence of heat is straightened again. Highly elastic (HE) yarn, good extensibility and large bulk
volume, as stabilized (set) yarn, lofty with less elongation
Air jet texturizing: Yarn is crimped in a turbulent current of air (gas or steam).Inelastic yarn
increased loftiness due to capillary thread loop formation fancy yarn
Knit/de-knit texturizing: Yarn is knitted, subjected to heat treatment and then de-knitted. Wavy
crimp, elongation, yarn produces a loftiness crepe effect
Stuffer box-texturizing: Yarn is crimped by means of compression. Zig-zag to wavy crimp,low
elasticity
Asymmetrical heat-texturizing: Contraction of the filaments on one side only is induced by
asymmetrical heat treatment.
Edge-texturizing: Yarn is pulled over an edge at an acute angle. Helical crimp, elastic yarn low with
increased bulk volume
Gear wheel-texturizing: Yarn is crimped between two sprockets.