Process For Continuously Treating Thread

Abstract

Thread is treated continuously and effectively with a liquid by passing the thread through a passage of tunnel-like treating device which is arranged alone or in series along a thread passage between one pair of thread delivery rolls, which device comprises a pair of plates, each having on its mutually facing inner surface a plurality of protrusions and grooves, forming the passage therebetween and having one or more inlets for sending the liquid pressurizedly therethrough that are located on the back of the plate. The treating liquid flows through the tunnel-like device, forming vortices in the grooves between the protrusions and thus the vortices contacting with thread accelerate treatment of the thread passing through the passage. The process and apparatus for treating thread continuously and effectively may be applicable for mercerization, dyeing, scouring, or the like.

Description

The present invention relates to a process for treating thread continuously and effectively, such as mercerization, scouring, dyeing or the like, and an apparatus used therefor.

Heretofore, cotton thread has been subjected to mercerization, dyeing, etc., in the form of hank and by a batch process in most cases. In those conventional processes, the productivity has been appreciably lowered due to troublesome preparation work before processing and clearance work after processing as well as difficulty in quality control of the process. In order to eliminate such drawbacks, many continuous treating systems and apparatuses therefor have so far been proposed. However, most of them require a large space due to their small productivity and besides, they can be run only at an extremely low speed. Therefore, an effective investment with respect to conventional systems is not expectable owing to their low efficiency, though the aforementioned troubles have been eliminated.

On the other hand, in scouring or dyeing of threads, there has been proposed a process wherein many ends of threads made into a rope or band form are run continuously and undergo those treatments. However, in such a process, variation and unevenness of tension, friction of the threads with a guide, etc. readily cause interentanglement or breakage of threads while processing, and whereby the bundle of threads in the rope form is often very difficult to divide into individual threads to be wound on a bobbin. To prevent threads in a hank from the interentanglement, a lace or lease yarn is usually employed to divide the band of threads into several groups and to tie them up. But, passing and tying a a lace transversely through a band of threads are considerably difficult hand tasks, which, therefore, have not so far been applied in continuous processes.

The present invention has its object to provide a novel process for treating threads continuously at a high operation speed, to overcome afore-mentioned difficulties in the treatment of threads.

Another object of the present invention is provision of a continuous process for treating threads wherein many ends of threads can be subjected simultaneously to a sufficient treatment at a high operation speed.

Further object of the invention is to provide an improved method for preventing multi-thread bundle from interentanglement while processing, whereby facilitating the division of the bundle into individual threads when wound on bobbins after treatment.

Still further object of the present invention is to provide an improved apparatus which is suitable for effecting the above-mentioned processes.

The above objects can be attained by the use of the apparatus of the present invention which comprises a tunnel-like treating device to pass threads continuously through. One of the features of the invention is to subject threads to successive steps of treatment, for instance, wetting, washing, swelling with caustic, etc., using a series of the above-mentioned apparatuses of the present invention.

The present invention has another feature where, in subjecting many parallel ends of threads simultaneously to the above treatment, the band of multi-thread is divided into an adequate number of groups; adjacent groups are alternately shifted towards a direction perpendicular to a plane formed by the band of parallel threads and separated from each others, forming an opening transversely through the multi-thread band; then a lace or lease yarn having its both free ends is laid across the band through the said opening, to prevent interentanglement of threads; and the lace is finally removed after the completion of the treatment.

Other features of the present invention will be hereafter enlightened by further illustration of the embodiment of the invention, referring to the accompanying drawing.

In the drawing:

FIG. 1 is a side sectional view of a tunnel-like treating device of the present invention;

FIG. 2 is a side elevation, partly in section, showing an embodiment of the present invention;

FIG. 3 is a plan view of the main part of the apparatus shown in FIG. 2;

FIGS. 4 and 5 are schematic side elevational views respectively showing an embodiment of the present invention;

FIG. 6 is a side elevation showing an embodiment of tension rolls;

FIG. 7 is a plan view showing a treating apparatus of the present invention which is provided with a device for preventing interentanglement of threads;

FIG. 8 is a side elevational view of the apparatus shown in FIG. 7;

FIG. 9 is a cross-sectional view of a band of threads showing a lace or lease yarn being laid across and through the band, in accordance with the present invention; and

FIG. 10 is a perspective view of a hank tied up by a lease yarn according to a conventional method.

In the above-mentioned drawing, there has been shown but one embodiment of the invention which is now deemed preferable, but it is to be understood that changes and modifications may be made within the scope of the appended claims without departing from the spirit of the invention.

Referring more in detail to the figures of the drawing, and first to FIG. 1, it will be seen that a tunnel-like treating device A comprises a pair of plates 1, 1', each having on one of its surfaces a plurality of protrusions and the plates are arranged so that their surfaces having protrusions face each the other, forming passage 2 therebetween. Treating liquid 3 is sent under pressure into the tunnel-like treating device through inlet 4 located at the center of the back of the plate 1, and flows towards both ends of the device, forming vortices 5 having their axes perpendicular to the flow-line of the liquid in grooves or recesses between protrusions. The vortices 5 contacting with thread accelerate washing action or other reactions between the treating liquid and thread Y passing through the passage 2. Such effect of the apparatus of the present invention is about three to five times that of a conventional stationary type or shower type saturator, when compared at the same dwelling time.

In FIGS. 2 and 3 is shown an embodiment of the present invention comprising the aforementioned tunnel-like treating device. Its main part comprises a pair of rolls 6, 6' which are so arranged that their axes are slightly inclined tow and each other, and two tunnel-like treating devices A which are fixed in parallel on and along the thread passage between the rolls 6, 6'. The thread Y to be treated passes through the aforementioned tunnel-like treating devices, undergoing the action of treating liquid and is wound around both rolls the required number of times. Consequently, comparatively short as the distance between those rolls 6, 6' may be, the thread can travel and be treated in the liquid for a sufficient period of time. Further, since the axes of both rolls are mutually inclined, the thread wound around those rolls is well separated and never lapped over the foregoing thread, so that no special yarn separator is required. An enhancement of the treating action can be attained, if required, by providing a shower 7 directed to the thread passage.

Treating liquid flows out of the tunnel-like treating device A, falls down and accumulates on the bottom of the casing 8 which houses the whole device. The treating liquid collected on the bottom is recirculated to the shower and tunnel-like treating devices through pumps P.sub.1, P.sub.2 and P.sub.3. Spent treating liquid is taken out of the treating system through an outlet 9 positioned at or near the bottom of the casing 8 and reactivated by means of purification or replenishment of fresh liquid before returning into the treating system.

The tunnel-like treating device of the present invention has a high treating ability as mentioned before and furthermore the inclined rolls 6, 6' have entirely solved problems in prior arts such as a big dimension of apparatus and small productivity, so that the apparatus of the invention can treat yarns and threads continuously with a high efficiency.

Another embodiment of the present invention is given in FIGS. 4 and 5, which is a system adapted for treating thread or yarn continuously in multi-step process and which comprises a plurality of treating units B corresponding to the apparatus shown in FIG. 2. Namely, the above mentioned treating units B.sub.1, B.sub.2, . . . . arranged in series and provided with feed rolls 10 between two adjacent treating units, are respectively connected by pipes with appropriate treating liquid supply source so that each treating unit can effect a treatment independently. The rolls 6, 6' and the feed rolls 10 are either synchronized or variable and adjustable in their surface speed by means of speed variator, etc. Accordingly, thread or yarn delivered from an appropriate thread supply means such as a creel stand, a beam and the like (not shown in the drawing) to the system, is subjected to a multi-step treatment under an adequate tension while it travels successively through the treating units B.sub.1, B.sub.2, . . . . , and thereafter taken up on a tube or skein to form a preferred shape of package such as a beam, cheese, hank or the like, as required by the following process.

The range shown in FIG. 4 is composed particularly for mercerization of cotton threads, which comprises eight treating units to perform successive steps of : preliminary wetting, first washing, saturation with caustic, tensioning, washing with hot water, second washing, neutralization and third washing. Namely a strand Y consisting of several to several hundred ends of threads is introduced into preliminary wetting unit B.sub.1 where the strand is treated with a wetting agent such as Turkey-red oil or the like at 20.degree.C - 80.degree.C. Thereafter the band is forwarded to the first washing unit B.sub.2 where excess wetting agent is removed. Then, in the caustic saturator unit B.sub.3, it is saturated with aqueous solution of 10 - 35 percent by weight, preferably 15 - 25 percent by weight of caustic soda at a temperature of 10.degree. - 60.degree.C, preferably 15.degree. - 25.degree.C. The band is further transferred to the tensioning unit B.sub.4 where it proceeds under tension to further the mercerization. In this unit, since no treating liquid is needed, the tunnel-like treating device A is neither required. Moreover, instead of winding the band around a pair of slant rolls, several rolls 11 can be used as shown in FIG. 6, to achieve the same performance. The band of threads then gets into the hot water washing unit B.sub.5 where the caustic soda is washed away with hot water at 50.degree.C - 90.degree.C, preferably 60.degree.C - 70.degree.C. Further, getting into the second washing unit B.sub.6, the band is washed with water at 10.degree.C - 30.degree.C, preferably 15.degree. - 25.degree.C. The washed band is led into the neutralization unit B.sub.7 where the remaining caustic soda is neutralized with an acid having a concentration of 1 - 2 percent. Finally, in the third washing unit B.sub.8, the acid remaining in the band is washed off with water at 15.degree. - 30.degree.C. Thus, a series of mercerization process is complteted and whereafter the band of threads is dried on an appropriate drying machine (not shown) and taken up on an appropriate winding machine (not shown) to form a package adapted for the following process.

In FIG. 5 which shows another embodiment of the present invention, i.e., a continuous dyeing system for cotton thread, six treating units B, . . . arranged in a series can effect independently color liquid padding, first washing, souring, second washing, soaping and third washing in this order.

In the tunnel-like treating device mentioned above, said protrusions may also be arranged alternately on the facing surface of said two plates and said inlet may be located in any place on the back of the plate, inlet number being singular or plural. Further, the tunnel-like treating device of the present invention may alternatively surround a passage of thread lapped around and between said rolls or open the side direction of itself (perpendicular plane to the plate), thereby flowing treating liquid out of there.

FIGS. 7 and 8 show an embodiment of the present invention which comprises a means for preventing interentanglement of threads while multi-thread band is processed. In these Figures, a band of threads 13 unwound from cheese 12 is continuously introduced into a treating apparatus 16 through guide 14 and gathering guide 15. After threatment, the band is divided into individual threads and taken up on bobbins separately, by means of divide and take-up machine 17. A least rod 18 is fixed between the aforementioned guide 14 and the gathering guide 15, which is laid across and through the band, dividing and separating it into several groups, at least three groups, of threads 19, 19, . . . . Further, opening rods 20, 21 are positioned one above the other between the gathering guide 15 and the lease rod 18. By the side of the opening rods 20, 21, there is provided a woof inserting device 22 including a package of lace yarn T such as thread, tape and the like. Between the above mentioned treating apparatus 16 and the divide and take-up machine 17, a beater for opening 23 and a spiked roll 24 are installed.

The band of threads 13 which is unwound from cheeses 2 and proceeds through guides 14 is divided by the lease rod 18 into several groups, at least three groups, of threads, adjacent groups being separated alternately to opposite directions. The number of threads comprising the group may be properly selected as long as the divide and take-up operation can be conducted without difficulty, and it is preferred to be not more than about 100. The upper groups of the divided threads are then led above the opening rod 20, while the lower groups are led below the opening rod 21. Thus, groups are separated into two, forming an opening 30. Into the opening 30, a lace or lease yarn T is picked intermittently with an appropriate interval from the woof inserting device 22. It is preferred the interval of picking corresponds to each 1,000 meters of the thread travelling. As the woof inserting device 22, any conventional filling insertion for loom, such as shuttle system, Rapier system or the like, may be employed and particularly in the case of the present invention, it is desired that the picked lace is cut to a certain length, forming its both free ends. Namely, the embodiment shown in FIGS. 7 and 8 comprises a carrier 25 which reciprocates across the band of threads and a catcher 26 located facing the carrier 25. The carrier 25 grips the end of the lease yarn and delivers it to the catcher 26. Simultaneously when the catcher 26 takes over the yarn, cutter 27 works to cut the yarn at a proper position. Thus, the band of threads wherein a lace is laid transversely over the entire width of the band, is shown in FIG. 9. The band of threads which laps the lace T therein is gathered by the gathering guide 15 into a strand which is further introduced in the treating apparatus 16 where subjected to a treatment as required. During the treatment, the lace or lease yarn T is held so securely by friction with threads that the initial relative position between the lace and threads remains substantially unchanged.

The strand which comes out of the treating apparatus 16 is again opened and beaten intermittently by beater for opening 23 to loosen the coherency of the strand which has been increased in the preceding process. Thereafter the band of threads is forwarded into the working zone of the spiked roll 24 where the lace or lease yarn T is cleared off by blades 28 on the surface of the spiked roll 24. The lease yarn removed and adhered to the above mentioned blades 28 is cleared by means of a brushing roll 29 which is mounted right under the spiked roll 24.

The thus treated band of threads is divided into several groups by lease yarns and sufficiently prevented from interentanglement, and moreover the number of threads contained in each group is limited to such extent as to facilitate the divide and take-up of the threads, so that consequently a thread package of excellent quality can be obtained.

The features and effect of the present invention will be further illustrated hereinafter in accordance with the following examples:

Example 1

Cotton thread was mercerized at the conditions given in Table 1, using the apparatus of the present invention as shown in FIG. 4. On the other hand, the cotton thread was mercerized by a coventional batch system mercerization process. The comparison in quality between the above mentioned two cases is given in Table 2. As is apparent from Table 2, the thread processed according to the present invention was of better quality and more uniform.

Condition

1. Thread: Cotton 60s/3 400 ends.

2. Operation speed: 120 meters per minutes.

3. Table 1 (Process Conditions)

Dwell Tension Treating Conc. Temp. Process time (g/den.) liquid (%) (.degree.C) (sec) Preliminary 30 1.2 Turkey- 80 wetting red oil 1st Wash- 30 1.5 25 ing Caustic 40 1.6 NaOH 25 20 saturation Tensioning 40 1.6 Washing 20 1.4 60 with hot water 2nd Wash- 20 0.9 25 ing Neutrali- 20 1.1 Acetic 1.5 zation acid 3rd Wash- 20 0.5 ing ##SPC1##

Rewettability was represented by a rate of weight increase of specimen when the specimen had been soaked in 1 percent aqueous solution of Silk Blue for 10 minutes.

Residual alkali was determined by titrating the specimen after washing with 1/10 N - sulphuric acid.

Ba value was determined by titrating the specimen with 1/10 N -- hydrochloric acid after soaking the specimen in 1/4 N -- Ba(OH).sub.2.

5. treating period of time

Present invention : 160 seconds

Conventional : 720 seconds

Example 2

Cotton thread was dyed at the conditions given in Table 3, using the apparatus of the present invention as shown in FIG. 5. On the other hand, the same cotton thread was dyed by conventional batch system dyeing process. A comparison in quality was made with respect to those products, the result of which is shown in Table 4. According to the process of the present invention, a product as excellent as the conventional product was obtainable at a high productivity.

Condition

1. Thread : Cotton 50s/3 400 ends

2. Operation speed : 30 meters per minutes

3. Table 3 (Process Conditions)

Process Dwell Treating liquid Conc. Temp. time (g/l) (.degree.C) (min.) Dyeing 5 1.Dyestuff, 0.5-2 50-60 Mikethrene Olive TS/F(manufactured by MITSUI KAGAKU KK) 2.Peretex FT No. 1 350(manufactured by MIYOSHI YUSHI KK) 3.Caustic soda 8 4.Hydrosulphite 5 1st 2 Water room Washing temp. Oxida- 2 1.Acetic acid 5 room tion 2.Potassium bi- 1 temp. chromate 2nd 2 Water room Washing temp. Soaping 3 1.Soap 2 80 2.Soda ash 2

Result

4. Table 4 (Comparison of quality)

Uniformity Light- Washing durabil- of dyeing stability ity Present Stain invention Good 4 or more 5 5 Conven- tional Stain (Batch Good 4 or more 5 5 system)

5. Treating period of time

Present invention : 14 minutes

Conventional : 70 minutes

Claims

What is claimed is:

1. A continuous process for treating thread with liquid treating agent, which comprises: continuously and repetitively moving a continuous thread means through a single treating zone with there being a plurality of parallel-moving, transversely spaced-apart courses of said thread means in said treating zone at any one time, continuously supplying treating liquid to said treating zone and moving said treating liquid through said treating zone in an overall flow direction which is parallel to the direction of movement of said thread through said treating zone, said treating liquid contacting the entire periphery of each course of said thread in said treating zone and the flow of the treating liquid in said treating zone including a plurality of spaced-apart flow segments disposed on opposite sides of the thread means and in each of which the liquid flows in a vortical fashion to contact the thread means and with the axis of each vortex being substantially perpendicular to the direction of movement of the thread, whereby the thread is subjected to a plurality of contacts with said treating liquid, with each contact being separated by movement of the thread outside of said treating zone.

2. A process as claimed in claim 1, in which said thread is continuously, repetitively and alternately moved through two of said treating zones, each of which has the same treating liquid supplied thereto.

3. A process as claimed in claim 2, in which said thread is showered with said treating liquid after it leaves one of said treating zones.

4. A process as claimed in claim 1, in which said thread is moved through a series of said treating zones and is treated in sequence with wetting agent, water, caustic agent, water, neutralizing agent and water supplied separately into the respective zones.

5. A process as claimed in claim 1, in which said thread is moved through a series of said treating zones and is treated in sequence with dyeing agent, water, souring agent, water, soaping agent and water, supplied separately into the respective zones.

6. A process as claimed in claim 1, in which said thread is prepared by separating a band of threads into at least three groups, moving adjacent groups alternately in opposite directions pependicular to the lengthwise extent of said groups to form a transversely extending opening between upper and lower layers of groups, inserting a lace or lease yarn transversely across the entire width of said opening between said upper and lower layers of groups, gathering the groups to form a thread which is then moved through said treating zone, removing the lace or lease yarn after the thread leaves the treating zone and opening the thread into individual thread groups and winding the individual thread groups on separate bobbins.

7. A process as claimed in claim 1, wherein said thread is a bundle consisting of a plurality of fibers which are substantially parallel with each other.

8. A process as claimed in claim 7, wherein said bundle is divided into a plurality of groups of fibers by a lace.