U.S. patent application number 17/599378 was filed with the patent office on 2022-06-09 for manufacturing method for manufacturing a cotton-containing product.
The applicant listed for this patent is H.M.C. GENERAL INCORPORATED ASSOCIATION, NAGOYA OSHIMA MACHINERY CO., LTD. Invention is credited to Hiroshi MIYAMOTO, Motohisa NOMA, Masataka OSHIMA, Yoji SUZUKI.
Application Number | 20220178070 17/599378 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-09 |
United States Patent
Application |
20220178070 |
Kind Code |
A1 |
MIYAMOTO; Hiroshi ; et
al. |
June 9, 2022 |
MANUFACTURING METHOD FOR MANUFACTURING A COTTON-CONTAINING
PRODUCT
Abstract
In order to manufacture a cotton-containing product of a cotton
material, when the cotton material is refined and bleached in the
state of a sliver, heating is performed, with steam, on the cotton
material with a chemical agent applied to the cotton material, and,
when the heating is performed, the steam is applied to the cotton
material in the state of a sliver sheet formed by arranging the
sliver in a sheet shape.
Inventors: |
MIYAMOTO; Hiroshi;
(Ishikawa, JP) ; NOMA; Motohisa; (Ishikawa,
JP) ; OSHIMA; Masataka; (Aichi, JP) ; SUZUKI;
Yoji; (Ishikawa, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
H.M.C. GENERAL INCORPORATED ASSOCIATION
NAGOYA OSHIMA MACHINERY CO., LTD |
Ishikawa
Aichi |
|
JP
JP |
|
|
Appl. No.: |
17/599378 |
Filed: |
December 23, 2019 |
PCT Filed: |
December 23, 2019 |
PCT NO: |
PCT/JP2019/050296 |
371 Date: |
September 28, 2021 |
International
Class: |
D06L 4/13 20060101
D06L004/13; D06B 5/04 20060101 D06B005/04; D06L 4/12 20060101
D06L004/12; D06L 4/75 20060101 D06L004/75 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 29, 2019 |
JP |
2019-067094 |
Claims
1. A manufacturing method for manufacturing a cotton-containing
product of a cotton material, comprising refining and bleaching the
cotton material in a state of a sliver, wherein, when the refining
and the bleaching are each performed, heating is performed, with
steam, on the cotton material with a chemical agent applied to the
cotton material, and wherein, when the heating is performed, the
steam is applied to the cotton material in a state of a sliver
sheet formed by arranging the sliver in a sheet shape.
2. (canceled)
3. (canceled)
4. The manufacturing method according to claim 1, further
comprising, after the sliver sheet is heated by applying the steam
to the sliver sheet, washing the sliver sheet while the sliver
sheet is being conveyed by at least one perforated conveying
medium.
5. The manufacturing method according to claim 4, wherein the at
least one perforated conveying medium comprises two perforated
conveying media comprising inner and outer mesh conveyors, wherein
a perforated drum is immersed in a washing liquid, wherein the
inner conveyor is disposed inside of the sliver sheet, and the
outer conveyor is disposed outside of the sliver sheet, and wherein
the washing of the sliver sheet comprises sucking a washing liquid
in the perforated drum while conveying the sliver sheet along an
outer periphery of the perforated drum, with the sliver sheet
sandwiched between the inner mesh conveyor and the outer mesh
conveyor, and passing the sucked washing liquid from outside of the
outer conveyor through the outer mesh conveyor, then through the
sliver sheet, then through the inner conveyor, and then through the
perforated drum.
6. The manufacturing method according to claim 1, wherein, after
the bleaching is finished, a function is applied to the cotton
material in the state of the sliver.
7. The manufacturing method according to claim 1, wherein after the
bleaching, the sliver is spun into thread.
8. (canceled)
9. (canceled)
10. A washing machine of a suction type comprising: a perforated
drum immersed in a washing liquid; a suction device configured to
suck the washing liquid from inside of the perforated drum; a pair
of inner and outer mesh conveyors between which a sliver sheet is
to be sandwiched; and a conveyor guiding device for conveying the
sliver sheet along an outer periphery of the perforated drum, while
sandwiching the sliver sheet between the inner mesh conveyor and
the outer mesh conveyor, with the inner mesh conveyor disposed
inside of the sliver sheet and the outer mesh conveyor disposed
outside of the sliver sheet, wherein the suction device is
configured to suck a washing liquid in the perforated drum, and
pass the sucked washing liquid from outside of the outer mesh
conveyor through the outer mesh conveyor, then through the sliver
sheet, then through the inner conveyor, and then through the
perforated drum, thereby washing the sliver sheet.
11. A production line for a cotton-containing product of a cotton
material, wherein a refining step and a bleaching step are
continuously performed on the cotton material, and wherein, in at
least one of the refining step and the bleaching step, the
production line includes: a steamer configured to heat a sliver
sheet of the cotton material by applying steam to the sliver sheet
after immersing the sliver sheet in a liquid; and the washing
machine of the suction type according to claim 10, which is
configured to wash the sliver sheet after the heating.
12. The manufacturing method according to claim 4, wherein, after
the bleaching is finished, a function is applied to the cotton
material in the state of the sliver.
13. The manufacturing method according to claim 5, wherein, after
the bleaching is finished, a function is applied to the cotton
material in the state of the sliver.
14. The manufacturing method according to claim 4, wherein after
the bleaching, the sliver is spun into thread.
15. The manufacturing method according to claim 5, wherein after
the bleaching, the sliver is spun into thread.
16. The manufacturing method according to claim 12, wherein after
the bleaching, the sliver is spun into thread.
17. The manufacturing method according to claim 13, wherein after
the bleaching, the sliver is spun into thread.
18. A production line for a cotton-containing product of a cotton
material, wherein a refining step and a bleaching step are
continuously performed on the cotton material, and wherein, in at
least one of the refining step and the bleaching step, the
production line includes a steamer configured to heat a sliver
sheet of the cotton material by applying steam to the sliver sheet
after immersing the sliver sheet in a liquid.
Description
TECHNICAL FIELD
[0001] The present invention relates to a manufacturing method for
manufacturing a cotton-containing product.
BACKGROUND ART
[0002] In recent years, in the cotton agriculture, development and
streamlining have been tried in, e.g., a cultivating method, or
improvement, research and development of seeds, to increase the
production of cotton. The basic material of produced cotton is
fibers comprising cellulose, but it contains first impurities such
as dirt and a minute amount of oil that adhere before it is
harvested as a plant. Therefore, the color of cotton is not white
but brownish. If these impurities remain, when dyeing a cotton
product formed of cotton, the impurities repel the dye, thus making
it difficult to dye the cotton product as desired.
[0003] Therefore, when processing fibers including cotton, it is
necessary to dye the fibers after whitening the fibers by removing
the above impurities. Specifically, a knitted cloth or a woven
cloth is manufactured by using spun raw threads, and is refined and
bleached in a dyeing factory equipped with discharged water
treating facilities and water supply environment, thereby obtaining
a greige before sewn.
[0004] Specifically, as a general method, spun threads formed into
a "skein shape" are refined, bleached and dyed in a package dyeing
machine or a hank dyeing machine, or spun threads formed into a
"cheese shape" are refined, bleached and dyed in a package dyeing
machine. In some cases, in order to reduce costs, refining and
bleaching are performed in a package dyeing machine, and dyeing is
performed in a hank dyeing machine.
[0005] When dyeing threads for jeans, a rope dyeing machine is
often used with the threads bundled together. However, the threads
are often refined and bleached in thread form by using a package
dyeing machine.
[0006] For example, the below-identified Patent Document 1 proposes
a processing method by which, when refining and bleaching a cotton
cloth, second impurities applied in thread spinning, spinning,
weaving, knitting steps are removed, too. The below-identified
Patent Document 2 proposes a chemical agent treating method when
performing glue removal and refining to fabrics. Also, in some
cases, a method is used by which raw threads are refined and
bleached in thread form, and then are kitted and woven, thereby
obtaining a pre-sewn greige.
PRIOR ART DOCUMENT(S)
Patent Document(s)
[0007] Patent document 1: Japanese Unexamined Patent Application
Publication No. 2002-238555 [0008] Patent document 2: Japanese
Patent No. 5554172
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0009] However, a large amount of water resources is consumed in
the above refining and bleaching steps. While, during the
manufacturing steps of cotton products, including the dyeing step,
a large amount of water resources is required and consumed, the
amount of water resources used for bleaching and refining among
these accounts for as high as 70 to 80% of the total amount of
water resources used to manufacture cotton products. Since a huge
amount of water resources is consumed to manufacture cotton
products, there are many countries and regions where cotton
products cannot be manufactured from home-grown cotton. This is one
of the main reasons why the cotton textile industry is shifting
from many countries where the cotton agriculture has developed to
other developing countries.
[0010] However, in developing countries, a situation often occurs
where water resources are not sufficiently purified after use.
Therefore, manufacturing cotton products could lead to worsening of
the environment of developing countries.
[0011] It is an object of the present invention to reduce the
amount of water resources consumed when manufacturing
cotton-containing products, thereby protecting the environment of
the respective countries and thus the global environment.
Means for Solving the Problems
[0012] In order to achieve the above object, in the present
invention, a cotton material is refined and bleached in the state
of a sliver.
[0013] The "sliver" is an aggregate of fibers formed in a strip
shape or a rope shape before twisting the cotton into threads.
Since, in this sliver state, the individual fibers have not been
entangled and have been separated compared to twisted threads,
chemical agents and water used for refining and bleaching easily
infiltrate into the individual fibers. Therefore, it is possible to
significantly reduce the amount of consumed water compared to
conventional methods in which twisted threads or fabrics are
refined and bleached.
[0014] Also, in the present invention, when the refining and the
bleaching are each performed in the sliver state, heating may be
performed with steam. Since, in the sliver state, the individual
fibers are exposed to the atmosphere, unlike twisted threads or
fabrics, steam is easily applied to the individual fibers without
being interrupted by the adjacent fibers. Therefore, after
immersion in chemical agents used for refining and bleaching, the
heating of the individual fibers with steam is smoothly performed
without being hindered by the adjacent fibers, and can be easily
performed at a high temperature to such an extent that the above
chemical agents sufficiently act on the fibers. Also, since steam
has a very low specific gravity compared to liquid water, compared
to heating, in a hot water bath, for refining and bleaching, it is
possible to significantly reduce the amount of consumed water
resources by using steam for heating. Also, compared to
conventional methods in which a hot water bath is used, and thus a
large amount of water needs to be heated, since the mass of steam
is significantly small compared to its volume, it is possible to
significantly reduce the amount of energy required and consumed for
heating with steam.
[0015] Also, in the present invention, when steam is applied to the
sliver, the sliver may be refined and bleached while being arranged
in a sheet shape. The sliver has not been twisted yet, but, if the
sliver is gathered in a rod shape, it may be difficult to apply
steam to the center of such a sliver. In contrast thereto, if the
sliver is arranged in a sheet shape, all of the fibers constituting
the sheet-shaped sliver are exposed, so that it is possible to save
the amount of consumed steam and the amount of heat required for
creating steam. Also, since slight friction is generated between
the adjacent fibers of the sheet-shaped sliver, and the
sheet-shaped sliver is kept wet by a chemical liquid, steam, etc.,
the sheet-shaped sliver can be sequentially processed as a
continuous sliver sheet while being conveyed.
[0016] Also, in the present invention, after the sliver sheet is
heated by applying steam to the sliver sheet, the sliver sheet may
be washed while being conveyed by at least one perforated conveying
medium. Since the sliver has not been twisted unlike threads, if
the sliver is pulled strongly in its length direction, the sliver
is likely to be separated, and thus it is difficult to convey the
sliver while being pulled like threads. By washing the sliver while
being placed on the at least one perforated conveying medium, it is
possible to covey and wash the sliver constituting the sliver
sheet, while applying little force to the sliver. The at least one
perforated conveying medium may be, e.g., a mesh conveyor.
[0017] The following may be adopted: The at least one perforated
conveying medium comprises two perforated conveying media
comprising inner and outer mesh conveyors, wherein a perforated
drum is immersed in a washing liquid, wherein the inner conveyor is
disposed inside of the sliver sheet, and the outer conveyor is
disposed outside of the sliver sheet, and wherein the washing of
the sliver sheet comprises sucking a washing liquid in the
perforated drum while conveying the sliver sheet along an outer
periphery of the perforated drum, with the sliver sheet sandwiched
between the inner mesh conveyor and the outer mesh conveyor, and
passing the sucked washing liquid from outside of the outer
conveyor through the outer mesh conveyor, then through the sliver
sheet, then through the inner conveyor, and then through the
perforated drum.
[0018] By rotating the sliver sheet along the periphery of the
perforated drum while being sandwiched between the perforated
conveying media, it is possible to make a washing liquid pass
through the sheet surface of the sliver sheet without applying a
force which causes separation of the sliver sheet, and it is
possible to save the space for washing. Also, by creating a
negative pressure due to suction of the washing liquid in the
perforated drum, it is possible to suck the washing liquid from
outside of the mesh conveyors sandwiching the sliver sheet to be
rotated along the outer periphery of the perforated drum, thereby
making it possible to wash the sliver sheet while generating a
constant liquid flow. Also, by circulating a portion of the sucked
washing liquid to the outside of the mesh conveyors in a water tank
storing the perforated drum, it is possible to reduce the amount of
consumed washing liquid. In a conventional general washing method,
an object is washed by bending and lifting up the object for water
replacement in washing tanks, and the washing efficiency depends on
how many times the object is bent and lifted up, and the number of
used washing machines. If such a conventional method is used, a
large number of washing machines will be required, and also the
sliver may be cut during processing in the bending and lifting up
step. In contrast thereto, by adopting a suction type as described
above, and washing the sliver sheet while being sandwiched between,
and conveyed by, the conveying media, it is possible to further
reduce the risk of sliver cutting. Also, while the above
conventional washing method requires a large number of long and
large washing machines, in the present invention, since the sliver
sheet is moved along the perforated drum, it is possible to
significantly shorten the space required for the water tank, and
thus to significantly reduce the amount of consumed water and the
size of a required factory site, compared to using the conventional
method.
[0019] After the bleaching is finished, a function may be applied
to the cotton material in the sliver state.
[0020] When applying functions to the fibers with various chemical
agents, too, it is advantageous to do so in the sliver state,
because this facilitates infiltration of the chemical
liquids/agents and heating, and reduces the amount of consumed
water resources, compared to applying functions in a hot water
bath. The cotton sliver neutralized and washed with hot water after
bleached is close to pure cellulose, and thus reacts quickly when
applying a function thereto, thereby increasing work
efficiency.
[0021] The sliver after bleached by the above method has been
sufficiently whitened in the sliver state. By spinning this sliver,
it is possible to obtain threads of which the individual fibers are
sufficiently white. In a conventional method in which threads are
first twisted, and then are refined and bleached, the inner
portions of the threads are less likely to be effectively refined
and bleached due to twisting; the threads need to be refined and
bleached with a large amount of water; and thread portions which
has not been sufficiently bleached tend to remain in the threads.
For threads obtained from the sliver after refined and bleached
according to the method of the present invention, since the threads
have been refined and bleached without generating a disadvantage as
described above caused by twisting, the individual fibers have been
sufficiently processed, and thus the quality is good.
[0022] For the sliver of a cotton-containing material after
bleached and refined according to the present invention, since the
sliver has been already bleached and refined in the sliver state,
it is possible to easily dye the sliver later. Also, since the
sliver has been already refined, it is possible to easily obtain a
textile product via various steps such as thread spinning, spinning
and cloth weaving. At this time, since refining and bleaching,
which tend to consume a large amount of water resources, have been
already performed to the fibers in the sliver state, it is possible
to significantly reduce the amount of water resources required for
manufacturing cotton products. It is possible to obtain not only a
100% cotton product formed of threads spun from the above sliver,
but also a cotton-containing product formed by blending together
the above threads and threads made of a fiber other than
cotton.
[0023] As a device for manufacturing a cotton-containing product by
processing the sliver according to the present invention, a washing
machine of a suction type may be used which comprises: a perforated
drum immersed in a washing liquid; a suction device configured to
suck the washing liquid from inside of the perforated drum; a pair
of inner and outer mesh conveyors between which a sliver sheet is
to be sandwiched; and a conveyor guiding device for conveying the
sliver sheet along an outer periphery of the perforated drum, while
sandwiching the sliver sheet between the inner mesh conveyor and
the outer mesh conveyor, with the inner mesh conveyor disposed
inside of the sliver sheet and the outer mesh conveyor disposed
outside of the sliver sheet, wherein the suction device is
configured to suck a washing liquid in the perforated drum, and
pass the sucked washing liquid from outside of the outer mesh
conveyor through the outer mesh conveyor, then through the sliver
sheet, then through the inner conveyor, and then through the
perforated drum, thereby washing the sliver sheet.
[0024] In other words, a production line for a cotton-containing
product of a cotton material may be used wherein a refining step
and a bleaching step are continuously performed on the cotton
material, and wherein, in at least one of the refining step and the
bleaching step, the production line includes: a steamer configured
to heat a sliver sheet of the cotton material by applying steam to
the sliver sheet after immersing the sliver sheet in a liquid; and
the above-described washing machine of the suction type, which is
configured to wash the sliver sheet after the heating.
Effects of the Invention
[0025] According to the present invention, it is possible to
significantly reduce the amount of water resources required for
manufacturing cotton-containing products; reduce a burden on the
environment; and manufacture cotton-containing products in more
areas.
[0026] Regarding conventional refining and bleaching of batch type,
threads after spun are refined for about 30 minutes in a refining
liquid such as a surfactant, an enzyme agent or an alkaline agent,
and then are bleached for 60 to 90 minutes in the same bath with,
e.g., a surfactant, caustic soda or hydrogen peroxide. If caustic
soda is used for bleaching, a lot of water and strong neutralizing
acid (sulfuric acid) are required for washing and neutralizing this
high alkalinity. This increases the amount of discharged processing
water, and increases the burden of discharged processing water due
to the its quality deterioration. Also, strong acid tends to damage
the device. Regarding refining and bleaching continuously performed
to a sliver, the use of strong alkali is not required; bleaching
reaction can be completed in about 3 to 8 minutes; and refining
reaction can be completed in 5 minutes or less. Such a
manufacturing method is excellent in that it also can reduce
processing time. Also, such a manufacturing method can reduce the
amount of energy required for heating water, and reduce even a
factory space required for processing. As a result thereof, it is
possible to construct a small textile factory of which the burden
on the environment is small, even in areas where it was difficult
to construct a textile factory, thereby making it possible to
vitalize the textile industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a flow chart schematically illustrating the steps
of a cotton-containing product manufacturing method according to
the present invention.
[0028] FIG. 2A is a plan view of a system used in the
cotton-containing product manufacturing method according to the
present invention.
[0029] FIG. 2B is a front view of FIG. 2A.
[0030] FIG. 2C is a left side view of FIG. 2A.
[0031] FIG. 3A is a plan view of a washing machine used in an
embodiment of the present invention.
[0032] FIG. 3B is a front view of FIG. 3A.
[0033] FIG. 3C is a left side view of FIG. 3A.
[0034] FIG. 4 is an enlarged front view of the washing machine used
in the embodiment of the present invention.
[0035] FIG. 5 is a schematic diagram of the washing machine of
suction type used in the embodiment of the present invention.
[0036] FIG. 6 is a photograph of a sliver sheer placed on a
stainless steel net.
[0037] FIG. 7 is a flow chart schematically illustrating the steps
of a different, cotton-containing product manufacturing method
according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0038] The present invention is described below in detail.
[0039] The present invention relates to a manufacturing method for
manufacturing a cotton-containing product using a cotton material,
and a cotton-containing product manufactured by this manufacturing
method. The "cotton-containing product" refers to both a pure
cotton product and a product containing cotton and another fiber.
The present invention is particularly suitable for a pure cotton
product.
[0040] The cotton material used in the present invention comprises
a fiber or fibers including cotton. Not only a 100% cotton material
but also blended and spun fibers comprising cotton and another
fiber can be used. Specifically, such blended and spun materials
include:
[0041] a cotton-and-Cannabis sativa-blended-and-spun material
formed by blending and spinning cotton and Cannabis sativa such as
ramie, linen or hemp;
[0042] a cotton-and-wool-blended-and-spun material formed by
blending and spinning wool and cotton;
[0043] a cotton-and-cashmere-blended-and-spun material formed by
blending and spinning cashmere and cotton;
[0044] a cotton-and-animal hair-blended-and-spun material formed by
blending and spinning cotton and another animal hair;
[0045] a cotton-and-silk-blended-and-spun material formed by
blending and spinning silk and cotton;
[0046] a cotton-and-regenerated cellulose fiber-blended-and-spun
material formed by blending and spinning cotton and a regenerated
cellulose fiber, e.g., lyocell such as Tencel (registered
trademark), cupra (copper ammonia rayon), polynosic, rayon, or
bamboo rayon; and
[0047] a cotton-and-synthetic fiber-blended-and-spun material
formed by blending and spinning cotton and a synthetic fiber such
as acetate fiber, nylon fiber or acrylic fiber.
[0048] In the present invention, a cotton material is processed in
the state of a sliver, which is an aggregate of fibers before being
twisted into threads. Specifically, the sliver is refined to remove
dirt and oil components attached to the cotton, and bleached to
whiten the brownish color. Basically, the bleaching is performed
after the refining. Since the fibers are not sufficiently entangled
in the sliver state, they will be disentangled when a strong force
is applied thereto. Therefore, in the present invention, the sliver
is preferably processed while being conveyed by a perforated
conveying medium (or media) having holes. Such conveying perorated
media include, e.g., a net, a group of chains, and a plate having
holes in its plate surface. If a net is used, its meshes act as the
holes. If a chain conveyor is used which comprises chains connected
together on a plane, the holes of the individual rings, and the
gaps between the respective rings act as the "holes". As a plate
having holes, for example, individual blocks constituting the
conveyor and each having holes in its plate surface can be used, or
a cylindrical plate constituting a cylindrical drum, and having
holes in its peripheral surface can be used.
[0049] In the present invention, the slivers are processed while
being placed on such a conveying medium. Instead of a single
conveying medium, a plurality of conveying media may be used
alternately, or the slivers may be sandwiched between a plurality
of conveying media. When placing the slivers onto a conveying
medium, the slivers are preferably arranged into sheets. The sliver
arranged in a sheet shape is referred to as "sliver sheet". By
arranging the sliver in a sheet shape, it is possible to handle the
sliver as a single aggregate due to the friction between the
individual fibers constituting the sliver, thus enabling the sliver
to have a strength required when conveyed and processed. This
prevents separation of the individual fibers even when subjected to
steam or a liquid flow as described later.
[0050] FIG. 1 shows a flow including a production line where the
above cotton material is processed in the sliver state to obtain a
cotton-containing product. The "cotton-containing product" is a
product comprising a fiber or fibers including cotton as with the
above cotton material, and such "products" include not only a
product of a 100% cotton material but also a product of blended and
spun fibers comprising cotton and another fiber. Specifically,
examples of the above products include, e.g., spun threads, woven
fabrics produced from threads, and clothes, towels and other
practical products that are made from woven fabrics. FIG. 1
exemplifies steps to obtain threads as the above product.
[0051] First, the sliver is taken out of a supply source 11, and
arranged in a sheet shape to form a sliver sheet. In terms of work
efficiency, the sliver sheet is preferably a seamless, continuous
sheet. The sliver sheet formed by arranging the sliver in this way
is continuously placed onto the above conveying medium, and refined
in a refining step 12. In the refining step 12, foreign objects
included in the raw cotton, such as plant leaves and stems, and
other undesired objects such oils and fats, and other impurities,
are removed before the next bleaching step 13. After the refining
step 12, the sliver sheet is sequentially introduced into the
bleaching step 13 as it is. In the bleaching step 13, color
components which look yellow or brown mainly derived from the
original color of the cotton are removed to whiten the fibers.
After the bleaching step 13, a post-processing step 14 is, if
necessary, performed, and a bleached sliver of which the individual
fibers have been refined and bleached thoroughly is obtained. After
a spinning step 15 where the bleached slivers are spun, threads are
obtained as the cotton product.
[0052] As the above sliver supply source, the Kens method may be
used or the wrapping method may be used. Also, in the first place,
the sliver per se is obtained by arraying and bundling raw cotton
by use of a carding machine. The sliver bundled in a strap shape
may be developed into a sheet shape later, or the sliver may be
developed into a sheet shape from the beginning. Fibers bundled
together to constitute a continuous sliver of cotton material are
developed into a sheet shape within the width range of the
conveying medium located within the widths of the machines used in
the subsequent steps, thereby sequentially forming the continuous
sliver sheet. The sequentially formed continuous sliver sheet is
then sequentially processed in the above-described steps. In order
to assist in this conveyance of the continuous sheet, the forming
speed at which the continuous sliver sheet is formed needs to be
equal to, or faster than, the processing speeds in the subsequent
steps. However, since the sliver or the sliver sheet needs to be
pulled until it is placed onto the conveying medium, it is
necessary to adjust the tensile load so as to prevent
disentanglement of the slivers.
[0053] An exemplary production line where the refining step 12 to
the post-processing step 14 are continuously performed on the
continuous sliver sheet is shown in the plan view of FIG. 2A, the
front view of FIG. 2B, and the side view of FIG. 2C when seen from
the side of a refining padder 21. These steps are sequentially
performed from left to right in FIGS. 2A and 2B.
[0054] First, the refining step 12 is described. In the refining
padder 21, a liquid immersion sub-step 12a is perform as a
preparation part of the refining step 12. The refining padder 21 is
configured to receive the continuous sheet-shaped sliver sheet 51
on an inwardly inclined receiving seat located at a lower portion
of its injection port. The refining padder 21 is further configured
to send the continuous sliver sheet 51 received on the receiving
seat to a refining liquid immersion portion 21a. When sending the
sliver sheet into the portion 21a, and feeding it within the
devices, a conveying medium such as a mesh conveyor is used which
can convey the continuous sliver sheet 51 while being placed on the
conveying medium. The refining padder 21 is further configured to
squeeze, in a pressure applying mangle device 21b, the continuous
sliver sheet to which a refining liquid was applied at the refining
liquid immersion portion 21a, and then feed it out of the refining
padder 21. The liquid immersion sub-step 12a does not particularly
require heating, and can be performed at normal temperature (room
temperature). The refining liquid is stored in the refining liquid
immersion portion 21a, and the continuous sliver sheet 51 is
immersed in the refining liquid at a speed of, approximately, not
less than 5 m/minute to 10 m/minute. In a general refining step for
refining threads, about four to five liquid tanks for storing a
refining liquid are prepared, and threads are continuously immersed
in these liquid tanks to infiltrate the refining liquid into the
fibers, or threads are processed for a long time with a
high-temperature chemical liquid. This is because cotton fibers are
covered with oil and fat, or pectin, and thus water-repellent,
i.e., do not absorb water. In contrast, in the present invention,
since the continuous sliver sheet 51 is immersed in the refining
liquid, and the individual fibers are entangled weakly in this
state, even though the continuous sliver sheet is water-repellent,
it is possible to sufficiently infiltrate the refining liquid into
the individual fibers by immersing the sliver sheet only once.
[0055] The above refining liquid has weak acidity, and preferably
has a pH of about not less than 3.0 and not more than 5.5. The
above refining liquid preferably contains, in addition to the acid
components, an acid-resistant penetrant, an enzyme catalytic agent,
a degassing penetrant, etc. The enzyme catalytic agent is a
chemical agent enabling effective refining under the
high-temperature conditions in the next steam heating sub-step 12b.
The degassing penetrant promotes replacement of air contained in
the slivers with the refining liquid. Since the degassing penetrant
quickens infiltration, by using the degassing penetrant, it is
possible to omit, for example, a pre-washing tank and a chemical
application tank, and thus to reduce the amount of water required
for the processing.
[0056] The roll-squeezing conditions of the pressure applying
mangle device 21b, which is located on the exit side of the liquid
immersion sub-step 12a, are preferably about 70 to 100%. However,
the continuous sliver sheet needs to be kept wet to some extent. In
a wet state, the continuous sliver sheer has a strength enough to
be able to maintain its shape in the subsequent processing, too,
due to the friction between the individual fibers. Preferably, the
sliver sheet is conveyed by the above conveying medium until
immediately before being sandwiched between the upper and lower
rolls, and conveyed again on the same conveying medium right after
being squeezed by the rolls.
[0057] Next, in a refining steamer 22, the steam heating sub-step
12b is performed to heat the continuous sliver sheet 51 to which
the refining liquid has been applied. Refining reaction is advanced
by steam filling the interior of a steamer tank into which the
continuous sliver sheet 51 with the refining liquid is sent. The
temperature of the interior of the steamer tank 22a is preferably
about not less than 98.degree. C. and not more than 105.degree. C.
If this temperature is too low, the steam will condense, so that
heat transfer may be insufficient. On the other hand, if the above
temperature is too high, an unexpected reaction may occur. The
reaction time in the steamer tank is preferably about not less than
1 minute and not more than 5 minutes. The steam pressure of the
introduced steam is preferably about not less than 0.3 MPa and not
more than 0.7 MPa. Since the continuous sliver sheet 51 has been
squeezed by the pressure applying mangle device 21b, although the
surface of the continuous sliver sheet 51 is wet, little water is
present on the surface. Therefore, molecules of steam, which are
sufficiently smaller than liquid waterdrops, easily come into
contact with the individual fibers, and quickly supplies a
sufficient amount of heat to heat the fibers, thereby making it
possible to advance the refining reaction in a short time. In order
to easily apply steam to the entire continuous sliver sheet 51, the
conveying medium for conveying the sliver sheet 51 preferably has
holes through which steam passes, as with a mesh conveyor.
[0058] Next, in a washing machine 23, a washing sub-step 12c is
performed to wash off the refining liquid that remains adhered to
the continuous sliver sheet 51 after the reaction.
[0059] Preferably, the continuous sliver sheet 51 is washed in the
washing machine 23, while being conveyed by a conveying medium
having holes. If individual sliver sheets are independently
immersed in a washing liquid, they could be disentangled. However,
by placing the continuous sliver sheet on a conveying medium having
holes, or by sandwiching the sheet 51 between conveying media
having holes, it is possible to continuously wash a large amount of
sliver while preventing disentanglement of, and damage to, the
slivers.
[0060] Especially in order to continuously wash the continuous
sliver sheet 51 without damaging the sliver sheet 51, by using
inner and outer mesh conveyors 53a and 53b as the conveying media
having holes; and immersing the continuous sliver sheet 51 in the
liquid, thus exposing the sliver sheet 51 to a liquid flow, with
the sliver sheet 51 sandwiched between the inner and outer
conveyors 53a and 53b, it is possible to wash the continuous sliver
sheet 51 while protecting the sliver sheet 51 by the conveyors on
both sides thereof.
[0061] As the washing machine 23, a normal washing machine can be
practically used. However, by using a washing machine 50 of the
liquid suction type, it is possible to maximize the advantage of
washing the fibers in the form of the continuous sliver sheet 51. A
single washing machine of the liquid suction type can produce a
washing effect roughly comparable to the washing effect of three to
four general washing machines of the replacement type. Since the
individual fibers of the continuous sliver sheet 51 are not twisted
together, it is possible to wash the individual fibers quickly by
liquid suction. Also, by liquid suction, it is possible to wash the
sliver sheet with a small amount of washing liquid, compared to
washing in a static liquid, and thus to reduce the amount of water
used. In a conventional arrangement in which threads or fabrics are
continuously washed in a static liquid, a long and large tank is
required for washing. By using the washing machine 50 according to
the present invention, it is possible to use a compact tank, and
realize an energy-saving factory, i.e., significantly reduce both
the consumption of water and the area of land occupied.
[0062] The washing machine 50 of the liquid suction type includes a
perforated drum 57 having holes and immersed in a washing liquid;
and a suction device for sucking the washing liquid from inside of
the perforated drum 57. The washing machine 50 further includes a
conveyor guiding device for conveying the continuous sliver sheet
51 along the outer periphery of the perforated drum 57 with the
continuous sliver sheet 51 sandwiched between the inner conveyor
53a located inside of the continuous sliver sheet 51 and the outer
conveyor 53b located outside of the continuous sliver sheet 51.
[0063] The washing machine 50 of the suction type, which includes
the above-described suction device and conveyor guiding device, is
now described while exemplifying its specific embodiment. FIGS. 3A,
3B and 3C show, respectively, a plan view, a front view and a left
side view of the embodiment. FIG. 4 shows an enlarged view of the
perforated drum 57, located at the center of the front view, and
its vicinity. FIG. 5 schematically illustrates the perforated drum
57 in the above views, and its vicinity.
[0064] The continuous sliver sheet 51 is introduced into the
washing machine 50 while being placed on a conveying medium or
media. In the embodiment, conveying media comprising two chain
conveyors (inner and outer conveyors 53a and 53b) are used. After
washing the continuous sliver sheet 51 while being sandwiched
between the inner and outer conveyors 53a and 53b, the continuous
sliver sheet 51 is fed while being placed on the outer conveyor 53b
to a pressure applying mangle device 52 and squeezed by the mangle
device 52 to remove excess liquid. FIG. 6 is a photograph of the
continuous sliver sheet 51 when discharged from the pressure
applying mangle device 52, received by another chain conveyor 53c,
and fed to the next step.
[0065] The continuous sliver sheet 51 conveyed from the upper left
side of FIG. 4 is introduced into washing water in a washing tank
54, while being sandwiched between a portion of the outer conveyor
53b that is moving from the lower side, and a portion of the inner
conveyor 53a that is moving from the upper side. The inner and
outer conveyors 53a and 53b, and the continuous sliver sheet 51
sandwiched between these conveyors are introduced into the washing
water so as to be moved along the outer periphery of the perforated
drum 57, which is immersed in washing water in the washing tank 54,
with the outer conveyor 53b facing outward. The perforated drum 57
has a cylindrical shape, and is formed with a plurality of holes
sufficient in number and size to such an extent that a sufficient
amount of washing water for washing the continuous sliver sheet 51
can be supplied through these holes.
[0066] The above conveyor guiding device is configured to guide the
conveyors such that the continuous sliver sheet 51 is continuously
conveyed along the outer periphery of the perforated drum 57. The
conveyor guiding device is constituted by a plurality of rollers,
described later, which are disposed such that (i) the continuous
sliver sheet 51 is sandwiched between a portion of the inner
conveyor 53a and a portion of the outer conveyors 53b; (ii) the
portions of the inner and outer conveyors between which the sliver
sheet is not sandwiched are continuously moved; and (iii) the inner
and outer conveyors and the sliver sheet are guided along the outer
periphery of the perforated drum 57. Conveyor driving devices for
driving the respective conveyors per se are preferably connected to
some of these rollers.
[0067] The inner conveyor 53a moves along a loop path at the upper
central portion of FIG. 4 as follows: The moving direction of the
inner conveyor 53a is changed to a downward direction by a roller
72b, and the inner conveyor 53a is moved in a right and downward
direction in FIG. 5, while forming a three-layer structure in which
the continuous sliver sheet 51 is sandwiched between the inner
conveyor 53a and the outer conveyor 53b, which is being fed from
the lower side. The moving direction of the inner conveyor 53a is
then changed to a left and downward direction in FIG. 5 by a roller
56b to which the inner conveyor 53a is hooked, and the inner
conveyor 53a is moved substantially completely around the outer
periphery of the perforated drum 57. At this time, while the inner
conveyor 53a comes into contact with the outer periphery of the
perforated drum 57, because the continuous sliver sheet 51 is moved
on the outer side of the inner conveyor 53a, it does not come into
contact with the perforated drum 57. After the inner conveyor 53a
is moved away from the perforated drum 57 while maintaining the
three-layer structure, the moving direction of the inner conveyor
53a is changed to a right and upward direction in FIG. 5 by a
roller 56a. When the moving angle of the outer conveyor 53b is
changed by a roller 71a, the continuous sliver sheet 51, supported
on the outer conveyor 53b, follows the outer conveyor 53b, and is
separated from the inner conveyor 53a. The moving direction of the
inner conveyor 53a is changed again by a roller 72a, and the inner
conveyor 53a moves past a tension roller 73a of a tensioner 70a and
reaches the roller 72b again. The tensioner 70a presses the inner
conveyor 53a from above, thereby applying a force such that the
inner conveyor is moved without loosening. The position where the
tensioner 70a is disposed is not limited to the position shown, but
the tensioner is preferably disposed at a position where the
tensioner does not overlap with the continuous sliver sheet 51.
This is because, if the tensioner is disposed at a position where
the tensioner overlaps with the sliver sheet, excess tension will
be applied to the continuous sliver sheet 51, and this may damage
the sliver.
[0068] The conveyor driving device for driving the inner conveyor
53a per se is configured such that the roller 72a is rotated by a
driving roller 68 rotated by a motor 66 via a chain 69, thereby
causing the entire inner conveyor 53a to move along a loop path.
The roller 72a is not limited to the roller shown. By the mechanism
for driving the inner conveyor 53a, and the below-described
mechanism for driving the outer conveyor 53b, the continuous sliver
sheet 51 sandwiched between the inner conveyor 53a and the outer
conveyor 53b is rotated along the outer periphery of the perforated
drum 57.
[0069] On the other hand, the outer conveyor 53b moves along a loop
path extending inside and outside of the washing tank 54 as
follows: The outer conveyor 53b is moved from the left in FIG. 5;
the moving angle of the outer conveyor 53b is changed to a right
and downward direction in FIG. 5 by a roller 71j; and the outer
conveyor 53b is moved in the right and downward direction, while
forming a three-layer structure in which the continuous sliver
sheet 51 is sandwiched between the outer conveyor 53b and the inner
conveyor 53a, which is moving from the upper side. Next, the moving
direction of the outer conveyor 53b is changed by the roller 56b,
and the outer conveyor 53b is moved substantially completely around
the perforated drum 57 as with the inner conveyor described above.
At this time, the inner conveyor 53 is located on the inner side of
the sliver sheet while being kept in contact with the perforated
drum 57, and the outer conveyor 53b is moved on the outer side of
the sliver sheet, with the continuous sliver sheet 51 sandwiched
between these conveyors. The moving direction of the outer conveyor
53b is then changed to a right and upward direction in FIG. 5 by
the roller 56a, and the moving direction of the outer conveyor 53b
is further changed to a less steep inclination angle by the roller
71a. As a result, the continuous sliver sheet 51 is separated from
the inner conveyor 53a, and fed to the contact point of two rollers
constituting the pressure applying mangle device 52, while being
placed on the outer conveyor 53b. The moving direction of the outer
conveyor 53b is changed to a downward/opposite direction by a
roller 71b disposed before the contact point of the above two
rollers. T moving direction of the outer conveyor 53b is further
changed by a roller 71c, then by a roller 71b, and then by a roller
71e, and further changed by a roller 71f located below the washing
tank 54 such that the outer conveyor 53b is fed in the left
direction in FIG. 4 under the bottom of the washing tank 54. The
moving direction of the outer conveyor 53b is then changed to the
upward direction by rollers 71g and 71h, and further changed to a
substantially horizontal direction by a roller 71i. The outer
conveyor 53b then moves past a tension roller 73b of a tensioner
70b, and reaches the roller 71j. Then, the outer conveyor 53b again
moves along the above-described loop path, while forming the
three-layer structure. The tensioner 70b also presses the outer
conveyor 53b from above, thereby applying a force such that the
outer conveyor is moved without loosening. As with the tensioner
for the inner conveyor 53a, the position where the tensioner 70b is
disposed is not limited to the position shown, but the tensioner
70b is preferably disposed at a position where the tensioner 70b
does not overlap with the continuous sliver sheet 51.
[0070] The conveyor driving device for driving the outer conveyor
53b per se is configured such that the roller 71d is rotated by the
driving roller 68, which is rotated by the motor 66 via the chain
69, thereby causing the entire outer conveyor 53b to move along the
loop path. The roller 71d is not limited to the roller shown.
[0071] The continuous sliver sheet 51 is conveyed along the outer
periphery of the perforated drum 57, while being sandwiched between
the inner and outer conveyors 53a and 53b. By conveying the sliver
sheet while being sandwiched between these conveyors, it is
possible to reduce the possibility of the sliver being severed due
to frictional resistance, contact resistance, etc. By introducing
and discharging the continuous sliver sheet 51 while being
sandwiched between the conveyors and rotated, the sliver, having a
low specific gravity and likely to float in the processing liquid,
can be sequentially submerged in the liquid, thus preventing cloth
floating and improving infiltration of the liquid.
[0072] The inner and outer conveyors 53a and 53b are conveying
media having holes through which a liquid flow can pass. The
perforated drum 57, along which these conveyors are guided, also
has, in its circumference, a plurality of holes through which a
liquid flow can pass. Since the individual fibers of the continuous
sliver sheet 51 are not twisted together, the continuous sliver
sheet 51 per se has a structure in which the individual fibers are
easily exposed to the liquid flow. The perforated drum 57 has a
suction port 59 through which washing water is axially sucked from
inside of the perforated drum 57 near its center. When washing
liquid is sucked through the suction port 59 by the suction device,
a negative pressure is generated in the interior of the perforated
drum 57, and thus liquid in the washing tank 54 is sucked into the
perforated drum 57, while passing through the outer conveyor 53b,
the continuous sliver sheet 51, the inner conveyor 53a, and the
perforated drum 57. By being exposed to this liquid flow, the
continuous sliver sheet 51 is washed quickly. Since the continuous
sliver sheet 51 is moved by the conveyors while being sandwiched
therebetween, its displacement or contact movement does not occur.
Therefore, it is possible to efficiently perform liquid replacement
in the fibers, and thus to wash the sliver sheet extremely
efficiently, compared to doing so in a simple washing machine.
[0073] After washing, the continuous sliver sheet 51 is squeezed by
the pressure applying mangle device 52 so as to remove water, and
then conveyed to the next step while being placed on the chain
conveyor 53c.
[0074] Since water in the washing tank 54 is continuously
discharged out of the system while being carried by the continuous
sliver sheet 51, it is desirable to supply water into the tank 54
as necessary. Specifically, water sucked through the axially
extending suction port 59 at the center of the perforated drum 57
is introduced into a pump 63 through a downwardly extending suction
pipe 62. The pump 63 constitutes the suction device configured to
suck water from inside of the perforated drum 57. The water is fed
from the pump 63 into an upwardly extending discharge pipe 64, and
is returned into the washing tank 54 from a spout 65 disposed above
a predetermined water level, through the discharge pipe 64. On the
other hand, the washed continuous sliver sheet 51 is fed into the
next bleaching step 13 after removing excess water with the
pressure applying mangle device 52 near the exit.
[0075] Next, the bleaching step 13 is described. In a bleaching
padder 31, a liquid immersion sub-step 13a is performed as a
preparation part of the bleaching step 13. The basic structure of
the bleaching padder 31, and the basic system thereof comprising a
bleaching liquid immersion portion 31a and a pressure applying
mangle device 31b are the same as those of the above refining
padder 21, in which the liquid immersion sub-step 12a is performed,
and a bleaching liquid is adhered to the continuous sliver sheet 51
in the liquid immersion sub-step 13a. However, the bleaching liquid
used here is different from the above refining liquid.
[0076] The above bleaching liquid is an alkaline liquid containing
a bleaching agent, and preferably has a pH of about not less than
8.5 and not more than 11.0. Hydrogen peroxide water can be suitably
used as the bleaching agent. The bleaching liquid preferably
contains a penetrant which promotes wetting, because such a
penetrant quickens infiltration of the chemical liquid, so that it
is possible to omit, e.g., a pre-washing tank and/or a chemical
liquid application tank, and thus to reduce the amount of water
required for the processing. Further preferably, the bleaching
liquid contains a hydrogen stabilizer and/or a reaction catalyst.
As an alkaline agent for alkalinizing the bleaching liquid, for
example, a chemical agent that shows weak alkalinity such as sodium
carbonate can be suitably used.
[0077] The roll-squeezing conditions of the pressure applying
mangle device 31b on the exit side of the liquid immersion sub-step
13a are preferably about 70 to 100%. However, the sliver sheet
needs to be kept wet to some extent. In a wet state, the continuous
sliver sheet has a strength enough to be able to maintain its shape
in the subsequent processing, too, due to the friction between the
individual fibers.
[0078] Next, in a bleaching steamer 32, a steam heating sub-step
13b is performed to heat, with steam in a steamer tank 32a, the
continuous sliver sheet to which the bleaching liquid has been
applied. The process in the steamer tank 32a can be performed under
conditions similar to those of the process in the above steamer
tank 22a. With the bleaching liquid applied, the continuous sliver
sheet is fed into the steamer tank, and subjected to bleaching
reaction by steam filling the interior of the steamer tank. While
the reaction generated by the heated bleaching liquid is different
from the reaction generated in the refining step 12, it is
preferable that the structure and conditions of the device are
basically the same as those of the corresponding device in the
refining step 12. However, the reaction time in the tank of the
bleaching steamer 32 is preferably about not less than 6 minutes
and not more than 8 minutes. This reaction time is longer than the
reaction time in the refining step, but can be significantly
reduced to at most half or less, and in some cases to one-fourth or
less, of the reaction time when conventional bleaching is performed
in a hot water bath. Therefore, compared to conventional methods,
it is possible to significantly reduce the consumption of energy or
water required for bleaching which requires a processing load
larger than refining requires.
[0079] Next, in a washing machine 33, a washing sub-step 13c is
performed to wash off the bleaching liquid that remains adhered to
the continuous sliver sheet after the reaction. By using a washing
machine 50 of the suction type as in the above washing sub-step
12c, it is possible to quickly wash off the bleaching liquid
without damaging the continuous sliver sheet 51, while reducing the
amount of water required for washing.
[0080] Thereafter, the post-processing step 14 is performed. First,
a neutralization sub-step 14a is performed in a neutralization
paddler 41. Specifically, since the continuous sliver sheet 51
still has alkalinity due to the bleaching liquid even after the
washing following the bleaching, the sheet 51 is neutralized in
this sub-step. Thereafter, a hot washing sub-step 14b is performed
in a hot water washing shower padder 42 to complete the sliver
sheet.
[0081] During the post-processing step, or before or after the
post-processing step, other function processes may be performed,
such as a durability/softening process, a washing durability
process, an antibacterial process, a quick-drying function process,
a sweaty odor eliminating process, an aging odor eliminating
process, and/or a water-repellent process. FIG. 7 shows an
exemplary flow in which a function applying step 17 is performed
after the post-processing step. The steps shown here other than the
function applying process 17 are the same as the steps shown in
FIG. 1. In a liquid immersion sub-step 17a of the function applying
step 17, the sliver sheet is immersed in a chemical liquid
corresponding to the functions to be applied. For example, in the
liquid immersion sub-step 17a, chemical liquids each corresponding
to one of the above-exemplified function processes are used.
Alternatively, chemical liquids each corresponding to two or more
of the above processes may be used. After being processed in the
neutralization sub-step 14a and the hot washing sub-step 14b of the
post-processing step 14, the sliver is neutralized, and thus can be
easily handled, and impurities have been removed from the sliver,
thus enabling chemical liquids for processing to easily react with
the sliver. Also, since the fibers to be processed are in the
sliver state, chemical liquids for function processes infiltrate
into the sliver quickly and suitably without being interrupted by
the individual fibers, thereby making it possible to apply an
effect to the sliver. Thereafter, in a drying sub-step 17b, liquid
components are removed, thereby making it possible to obtain a
sliver which produces a high effect. By, in the spinning step 15,
spinning this sliver into threads, it is possible to obtain a
cotton product in which the expected functions are suitably applied
to the individual fibers. Thus, it is possible to significantly
reduce not only the consumption of water and energy required for
the function processes, but also the space required for these
processes, compared to conventional methods in which these
functions are applied to threads or fabrics.
[0082] Thereafter, though not shown, the sliver is preferably dried
in the form of the continuous sliver sheet 51. In a wet state, the
sliver sheet has a certain degree of strength due to increased
frictional forces between the fibers, but this strength decreases
after drying. Therefore, the sliver sheet is preferably dried while
being placed on a conveying medium having holes. The dryer used for
drying preferably has a structure which can prevent excessive
dispersion of liquid due to the air volume, wind speed and wind
pressure during drying. Hot air is blown out from the interior of
the dryer to the upper and lower sides of the dried object. The
wind outlet of the dryer preferably has a structure which allows
hot air to easily pass through the gaps between the fibers of the
continuous sliver sheet. The heat source required for drying may be
steam, gas or an electric heater. It is preferable that the
temperature of applied heat can be selectively changed between
70.degree. C. and 180.degree. C., depending on the material of
cotton to be dried. As a result of fully drying the continuous
sliver sheet, by the function of the dryer which can control wind
pressure and wind volume, it is possible to obtain a continuous
sliver sheet bulging like the shape of the continuous sliver sheet
when injected.
[0083] In this way, it is possible obtain a bleached sliver, or a
sliver to which the above functions have been applied by additional
function processes. The obtained continuous sliver sheet is spun
into threads (spinning step 15) after being formed into the shape
of KGY slivers having a thickness of about 1 KGY. In order to form
the continuous sliver sheet into the KGY slivers, either one of the
following first and second methods may be selected. In the first
method, as in a normal, raw cotton spinning step, the sliver sheet
is processed in a blending and blowing machine, and then processed
in a drawing frame via. e.g., a carding machine, thereby obtaining
the KGY slivers for spinning. In the second method, individual
slivers separated from the sliver sheet and each distributed as a
single sliver are injected into a drawing frame as they are,
thereby obtaining the KGY slivers for spinning. The KGY slivers
formed by either of the first and second methods can be spun at a
desired thickness into threads having a function according to the
desired thickness. In the first method, more manufacturing steps
and more time are required, thus increasing the cost. On the other
hand, in the second method, since the processed slivers can be
injected into a drawing frame as they are, it is possible to obtain
spun threads in a short time without increasing the cost, and thus
to streamline production. In the second method, since the
sheet-shaped sliver after dried needs to be separated into the
individual slivers by a sliver separating device, this device is
preferably prepared beforehand as a sliver separating and
distributing device so as to be additionally usable when required
later.
[0084] In order to obtain a woven fabric and a practical product,
after the steps in FIG. 1, the step of combining threads together
to obtain a fabric or fabrics, and the step of forming the
fabric(s) into a predetermined shape by cutting, sewing, etc. are
added.
EXAMPLES
[0085] Examples are described below in which refining and bleaching
of slivers using steam according to the present invention were
actually performed. Whiteness degree was evaluated using JIS
whiteness degree and Hunter whiteness degree, and measured using a
CR410 colorimeter of Konica Minolta. The results are shown in the
following Table 1.
TABLE-US-00001 TABLE 1 Refining method L* a* b* JIS value L a b
Hunter value Example 1 Refining with no 96.06 -1.43 2.49 84.3 94.95
-1.45 2.44 94.21 degassing penetrant Example 2 Refining with 96.2
-1.4 2.37 84.89 95.13 -1.38 2.42 94.39 degassing penetrant
Comparative Batch refining, steam 95.78 -1.45 2.95 82.58 94.66
-1.46 2.88 93.76 Example 1 bleaching
Examples 1 and 2
[0086] In the refining step using steam, refining was performed
with refining liquids each containing chemical agents as shown in
the below-inserted Table 2. These chemical agents are acid refining
agent--chemist DN (produced by Satoda Chemical Industrial Co.,
Ltd.); acid-resistant penetrant--anizol MA-27 (produced by Satoda
Chemical Industrial Co., Ltd.); enzyme catalytic agent--AC600
(produced by RAKUTO KASEI INDUSTRIAL CO., LTD.); and degassing
penetrant--MAC-N2 (produced by Hokko Chemical Co., Ltd.). After the
corresponding refining liquid was applied to each sliver by the
refining padder at normal temperature, the sliver was treated with
steam of 100.degree. C. for 3 minutes, and washed by the washing
machine of the suction type shown in FIGS. 3A to 3C and FIG. 4.
Thereafter, the sliver was bleached as described below.
TABLE-US-00002 TABLE 2 Comparative Used chemical agent Example 1
Example 2 Example 1 Acid refining agent-Chemist DN 1.2 g/L 1.2 g/L
1.5 g/L Penetrant-anizol MA27 5.0 g/L 5.0 g/L 2.0 g/L Enzyme
catalytic agent-AC600 5.0 g/L 5.0 g/L 5.0 g/L Degassing
penetrant-MAC-N2 nil 5.0 g/L -- ph 4.5 5.0
Comparative Example 1
[0087] Batch refining was performed by immersion in a refining
liquid. Specifically, an oven backet made of stainless steel to be
placed into the cheese dyeing machine produced as a processing
machine by HISAKA WORKS, LTD. and described in Japanese Patent No.
554172 was prepared, and a sliver was placed into this oven backet,
and processed/treated for 30 minutes at a liquid temperature of
50.degree. C. After washing the sliver, the sliver was bleached
with steam, by use of the same chemical agents, and under the same
condition, as used in bleaching in Example 1.
Examples 1 and 2, Comparative Example 1: Bleaching
[0088] In both the Examples and the Comparative Example, bleaching
was performed with steam. Specifically, a bleaching liquid was
applied to the bleaching padder, and each sliver was treated for 3
minutes with steam of 100.degree. C. Then, after squeezing the
beaching liquid out from the sliver by use of the pressure applying
mangle device on the exit side, the sliver was washed by the
washing machine of the suction type shown in FIGS. 3A to 3C and
FIG. 4, and the sliver was neutralized and washed with hot water.
The bleaching liquid contains chemical agents as shown in the
below-inserted Table 3. These chemical agents are bleaching
agent--hydrogen peroxide 35% (produced by ADEKA);
penetrant--MAC-25S (produced by Hokko Chemical Co., Ltd.);
stabilizer--Hokutol 110 (produced by Hokko Chemical Co., Ltd.);
stabilizer--Neolate PL-3 (produced by NICCA CHEMICAL CO., LTD.);
reaction catalyst--Catalyst OX (produced by Satoda Chemical
Industrial Co., Ltd.); and alkaline agent--sodium carbonate (soda
ash) (produced by Tokuyama). The pH was 10.3.
TABLE-US-00003 TABLE 3 Bleaching agent-hydrogen peroxide 35% 80.0
g/L Penetrant-MAC-25S 10.0 g/L Stabilizer-Hokutol 110 10.0 g/L
Stabilizer-Neolate PL-3 20.0 g/L Reaction catalyst-Catalyst OX 30.0
g/L Alkaline agent-sodium carbonate 15.0 g/L
[0089] The treatment time in steam refining was 3 minutes, whereas
the treatment time in batch refining was 30 minutes. In steam
refining, the amount of required treatment liquid is substantially
equal to the amount of each processed sliver, whereas, in batch
refining, the amount of required treatment liquid is about 10 times
larger than the amount of the processed sliver. While, compared to
steam refining, a lot of treatment time is required, and a large
amount of processing liquid is discharged in batch refining, by
using the present invention, it is possible to reduce the treatment
time and the amount of discharged water, and thus to reduce
required energy, a burden on the environment, etc. Also, the
whiteness degree of each sliver refined with steam is higher than
that of the sliver refined in batch form, and the whiteness degree
of the sliver refined with steam using the degassing penetrant is
higher than that of the sliver refined with steam without using the
degassing penetrant, thus improving its actual quality, too.
DESCRIPTION OF REFERENCE NUMERALS
[0090] 11: Supply source [0091] 12: Refining step [0092] 12a:
Liquid immersion sub-step [0093] 12b: Steam heating sub-step [0094]
12c: Washing sub-step [0095] 13: Bleaching step [0096] 13a: Liquid
immersion sub-step [0097] 13b: Steam heating sub-step [0098] 13c:
Washing sub-step [0099] 14: Post-processing step [0100] 14a:
Neutralization sub-step [0101] 14b: Hot washing sub-step [0102] 15:
Spinning step [0103] 17: Function applying step [0104] 17a: Liquid
immersion sub-step [0105] 17b: drying sub-step [0106] 21: Refining
padder [0107] 21a: Refining liquid immersion portion [0108] 21b:
Pressure applying mangle device [0109] 22: Refining steamer [0110]
22a: Steamer tank [0111] 23: washing machine [0112] 31: Bleaching
padder [0113] 31a: Bleaching liquid immersion portion [0114] 31b:
Pressure applying mangle device [0115] 32: Bleaching steamer [0116]
32a: Steamer tank [0117] 33: Washing machine [0118] 41:
Neutralization paddler [0119] 42: Hot washing shower padder [0120]
50: Washing machine [0121] 51: Continuous sliver sheet [0122] 52:
Pressure applying mangle device 52 [0123] 53a: Inner conveyor
[0124] 53b: Outer conveyor [0125] 53c: Chain conveyor [0126] 54:
washing tank [0127] 56a, 56b: roller [0128] 57: Perforated drum
[0129] 59: Suction port [0130] 60: Overflow [0131] 62: Suction pipe
[0132] 63: Pump [0133] 64: Discharge pipe [0134] 65: Spout [0135]
66: Motor [0136] 68: Driving roller [0137] 69: Chain [0138] 70a,
70b: Tensioner [0139] 71a to 71i: Roller (for the outer conveyor)
[0140] 72a, 72b: Roller (for the inner conveyor) [0141] 73a, 73b:
Tension roller
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