PROCESS AND APPARATUS FOR CONTINUOUS DYEING OF ELONGATE TEXTILE MATERIAL

Abstract: A process and apparatus is disclosed for dyeing an elongate textile material (M) with different colors at predetermined intervals in a substantially continuous, uninterrupted cycle of operation. The apparatus (10) comprises a plurality of dye baths (20a, 20b) exchangeable one with another, a nip and guide roll assembly (22) rotatable into dyeing position in timed relation to the particular dye bath which has been exchanged; an orienting guide roll assembly (25, 32) carrying thereon a plurality of guide rolls (27a - 27d) and a cam plate (31) adapted to retract one of the guide rolls (27a - 27d) away from the path of dyed material (M′), and a cylindrical drum drier having a plurality of apertures (39, 40, 41) for the passage of dyed and undyed materials, respectively.

Description: This invention relates to a process and apparatus for continuous dyeing of elongate textile material. More particularly, the invention is directed to the production of an elongate textile material in the form of yarn, tape and the like which is finished with alternately different colors in a substantially continuous cycle of operation. Colored fabric tapes widely used for slide fasteners are typically produced by for example weaving a monochrome warp yarn with weft yarns having different colors at predetermined intervals such as shown in Figure 4 of the accompanying drawings, the resulting tape having a stripe pattern with alternately changed color zones. A typical process known in the art for continuously dyeing yarns or elongate fabric tapes usually comprises a first stage of scouring, washing and drying and a second stage of dye-depositing, thermosol treating, washing, rinsing and drying. Apparatus for this process involves a dye bath equipped with a padding roll and reversibly supported so that an initial dye liquor therein is removed, followed by washing the bath and the roll for replacement with a next different dye liquor. This dye replacement further entails the necessity of washing a nip roll associated with the padding roll and other rolls guiding the material which has been dyed. In some cases, an elongate tape is spliced at predetermined intervals for dyeing with different sets of colors. The conventional dyeing process referred to above would involve certain losses of undyed yarn incurred during the course of dye replacement and roll washing, the undyed yarn portions being removed upon dye finish to permit splicing of adjacent effective portions of the yarn that has been dyed. This loss of yarn is objectionably great, and in addition there would inevitably be surface irregularities on a product fabric woven from such spliced yarns, or else spliced joints of the yarn would become dislodged. In an attempt to eliminate the above material loss in the dyeing of tapes, it was a common practice to use splicing strips interconnecting adjacent tape portions during dyeing. This however is tedious and time-consuming for the extra work to attach and detach the splices. EP-A-0 081 718, on which the preamble of claim 1 is based, discloses a process of dyeing an elongate textile material with a variety of colours at predetermined intervals in a substantially continuous, uninterrupted cycle of operation, said process comprising the steps of: - depositing a dye on said textile material to produce a dyed material; orienting a direction of feed of said dyed material; passing said dyed material through a first section of a dryer assembly to dry said dye; washing said dyed material; rinsing said dyed material; and drying said dyed material by passing it through a second section of said dryer assembly. However, the process disclosed in EP-A-0 081 718 comprises dying the textile material at a number of printing stations. Each printing station dyes the material with dye of one colour. EP-A-0 081 718 also discloses an apparatus for dyeing an elongate textile material with a variety of colours at predetermined intervals. The apparatus comprises a number of printing stations, and each printing station dyes the material with dye of one colour. With the foregoing difficulties of the prior art in view, the present invention seeks to provide a novel process of and an apparatus for dyeing an elongate textile material with different colors at predetermined intervals in a substantially continuous, uninterrupted cycle of operation; that is, without discontinuing the feed of the material. The invention further seeks to provide a novel process and apparatus which is capable of continuously dyeing a variety of textile materials in small lots at increased rate of yield. According to a first aspect of the present invention there is provided a process of dyeing an elongate textile material with a variety of colours at predetermined intervals in a substantially continuous, uninterrupted cycle of operation, said process comprising the steps of: - depositing a dye on said textile material to produce a dyed material; orienting a direction of feed of said dyed material; passing said dyed material through a first section of a dryer assembly to dry said dye; washing said dyed material; rinsing said dyed material; and drying said dyed material by passing it through a second section of said dryer assembly; said process being characterised in that it further comprises the steps of (i) scouring the material, (ii) washing the material and (iii) drying the material by passing it through a third section of said dryer assembly before the dye is deposited on said material; in that said textile material is dyed at a single dye-depositing station; in that the process further comprises the steps of:- exchanging a dye bath containing a dye of one colour with another dye bath containing a dye of another colour at said dye depositing station; and simultaneously exchanging a nip roll and a guide roll with another nip roll and another guide roll respectively, said nip rolls and said guide rolls being mounted alternately on a rotatable support means; and it that the process further comprises the step of thermosol setting the dyed material after the dyed material has passed through the second section of said dryer assembley. According to a second aspect of the present invention there is provided an apparatus suitable for dyeing an elongate textile material in a variety of colours at predetermined intervals in a Substantially continuous, uninterrupted cycle of operation, said apparatus comprising: - means for dyeing said textile material to produce a dyed textile material; a dryer assembly having first and second apertures for the passage of said dyed material; and means for orienting the direction of feed of the dyed textile material so that said dyed textile material passes through said first aperture of said dryer assembly; said apparatus being characterised in that said means for dyeing said textile material comprises:- a single dye-depositing station; and at least two dye baths, each of said dye baths being moveable towards and away from said dye-depositing station whereby, in operation, a dye bath containing a dye of one colour can be exchanged with another dye bath containing a dye of another colour at said dye depositing station; in that said means for orienting the direction of feed of the dyed textile material comprises a first orienting guide roll assembly including a support means carrying around its periphery a plurality of spaced orienting rolls, said support means being rotatable to take one of said rolls out of engagement with said dyed material and to bring another of said rolls into engagement with said dyed material; in that said apparatus further comprises a second orienting guide roll assembly for re-orienting the direction of feed of the dyed material after the dyed tape has passed through said dryer assembly, said second orienting guide roll assembly being similar in structure and to said first orienting guide roll assembly; in that said dryer assembly is in the form of a cylindrical drum; and in that said dryer assembly comprises a third aperture, said undyed material passing through said third aperture. The above and other objects and features of the invention will be better understood from reading the following detailed description with reference to the accompanying drawings. Figure 1 is a diagrammatic equipment layout utilized to explain the construction and operation of an apparatus embodying the invention; Figure 2 is a diagrammatic side elevational view on enlarged scale of a guide roll assembly constituting part of the inventive apparatus; Figure 3 is a diagrammatic block diagram utilized to explain the process of the invention; Figure 4 is a diagrammatic plan view of an elongate textile material dyed in the form of a yarn; Figure 5 is a diagrammatic plan view of a tape woven from the yarn of Figure 4 ; and Figure 6 is a diagrammatic plan view of an elongate textile material dyed in the form of a tape. Referring now to the drawings and Figure 3 in particular, there are illustrated the various stages or steps constituting the process of the invention which comprises a first treatment stage including scouring a textile material M as at 100, first-washing the material M as at 110 and first-drying the material M as at 120 and a second treatment stage including dye-depositing the material M as at 130, second-drying the material M as at 140, thermosol-setting the material M as at 150, second-washing the material M as at 160, rinsing the material M as at 170 and final-drying the material M as at 180. In the case where the textile material M is to be treated with a single color dye, it is transferred from the first-drying station 120 to the dye-depositing station 130, thence directly to the second-drying station 140. When treating the material M with two or more different coloring dyes as contemplated under the invention, the process also includes the step 190 of exchanging the dye liquors and the step 200 of exchanging the nip rolls and their associated guide rolls, which steps are carried out while the material M is being continuously fed. The process of the invention further includes the step 210 of exchanging the orienting guide rolls in a first assembly during transfer of the plurally dyed material M' from the dye-depositing station 130 to the second-drying station 140 and the step 220 of exchanging the orienting guide rolls in a second assembly during transfer of the material M' from the second-drying station 140 to the thermosol setting station 150. Reference now to Figure 1 shows a dyeing apparatus which is used to carry the above process into practice in accordance with the invention. The apparatus generally designated at 10 comprises a scouring bath 11 and a washing bath 12 disposed horizontally parallel therewith. The baths 11 and 12 have dip rolls 13 and 14 respectively immersed in their respective treatment liquors. A first drive roll 15 is located above and intermediate between the dip rolls 13 and 14 and feeds a starting undyed elongate textile material M which trains around the scouring dip roll 13 and then around the washing dip roll 14. The textile material M moves upwardly from the washing bath 12 as it is fed by and around a second drive roll 16 and enters into a first-drying section D₁ in a drier assembly D. The material M advances around a third drive roll 17 located in parallel with the second drive roll 16 across the drier assembly D. As it moves past around a guide roll 18, the material M is oriented to travel in a horizontal path toward a dye-depositing station 19 to which a plurality of dye-depositing baths 20a, 20b each are successively transported in a horizontal direction. Each of the dye baths 20a, 20b contains one of a selected set of color dye liquors L and accommodates a padding roll 21a (21b) which transfers the dye liquor to the textile material M in cooperation with a nip and guide roll assembly 22 including nip rolls 22a, 22b and guide rolls 24a, 24b mounted on a support disc member 23. The disc member 23 is provided peripherally with a plurality of nip rolls 22a, 22b and guide rolls 24a and 24b alternating in equally spaced position with each other as shown in Figure 1. The number of the nip rolls and the guide rolls may vary with the number of the dye baths 20a, 20b corresponding to the number of dye colors to be applied onto the textile material M. In the presently illustrated embodiment, there are two vertically, diametrically opposed nip rolls 22a and 22b, two horizontally diametrically opposed guide rolls 24a and 24b on the support disc 23 for applying two different dye liquors from the respective dye baths 20a,20b which may be conveniently arranged to move toward and away from the operative position in which they alternately come into rotative engagement with the nip roll 22a or 22b. The textile material M while in continuous travel is dyed in contact between the padding roll 21a and the nip roll 22a at the dye-depositing station 19. As the material M is deposited with a dye from the dye bath 20a over a predetermined length, the support disc 23 rotates 180° to bring the other nip roll 22b into contact with the material M over the next predetermined length against the padding roll 21b in the dye bath 20b which has been exchanged with the previous dye bath 20a, and the material M is thus deposited with another different dye from the bath 20b. Exchange of the nip and guide rolls on the support disc 23 is coincidental with that of the dye baths 20a and 20b and only instantaneous to leave a small dye-free space portion S (Figure 6) between adjacent leading and ensuing sections of the material M' which has been dyed. Designated at 25 is a first orienting guide roll assembly located above the nip and guide roll assembly 22 and adapted to orient the direction of travel of the material M' from vertical to horizontal toward the drier assembly D. The orienting guide roll assembly 25, as better shown in Figure 2, comprises a rotary support disc 26 carrying around its periphery a plurality of equally spaced orienting guide rolls 27a - 27d for alternately engaging and guiding the material M' toward the drier assembly D. Each of the guide rolls 27a - 27d is rotatable about a pin 28 received in an elongated slot 29 and is biased normally radially toward the axis of the disc 26 by the action of a spring 30 accommodated in the slot 29. A polygonal cam plate 31 is fixedly secured to a machine frame and adapted to come peripherally into abutting engagement with the pin 28 via roller 28' thereon to impart a camming action to each of the orienting guide rolls 27a - 27d such that only a selected one of these rolls engages the material M' at the position of orientation thereof, while the rest of the rolls on the disc 26 are retracted from the path of travel of the material M'. To this end, the cam plate 31 has a first cam surface 31a engageable with the roller 28' of the guide roll 27a to retain the latter in guiding engagement with undyed portion of the material M', a second cam surface 31b extending substantially parallel with the horizontal run of travel of the material M, a third cam surface 31c sloped downwardly from the second cam surface 31b to retract the the roll 27a away from the path of the material M' and extending arcuately to engage with the other rolls 27b - 27d while the roll 27a is in guiding engagement with the material M' and a fourth cam surface 31d extending vertically in parallel with the vertical path of the material M' so that the roll 27d following the first or in-service roll 27a contacts the material M' while moving upwardly toward the point of orientation of the material M' for exchange with the roll 27a. The dye-free space portion S on the elongate textile material M defined between the trailing end of a leading dyed portion and the leading end of the next following or ensuing dyed portion is detected by means not shown when having approached the position of the first orienting guide roll 27a (at which the direction of travel of the material M' is changed from vertical to horizontal), whereupon the support disc 26 begins to rotate counterclockwise as viewed in the drawings, causing the first roll 27a to move horizontally toward the drier assembly D along the second cam surface 31b until the roll 27a reaches and descends along the third cam surface 31c to disengage from the material M'. Departure of the first roll 27a is substantially coincidental with arrival via fourth cam surface 31d of the ensuing roll 27d at the position of orientation of the material M'. Thus, exchange of the orienting guide rolls 27a - 27d is effected in succession by intermittent rotary movement of the disc 26 whereby it is made possible to eliminate the risk of transferring the dye on dyed portion to adjacent dyed portions of the elongate material M' which would otherwise occur to stain or discolor the material M'. Dyed material M' upon orientation as the orienting guide roll assembly 25 moves on horizontally and enters the drier assembly D through a second-drying section D₂, and it thence arrives at a second orienting guide roll assembly 32 which is identical in construction and function with the first assembly 25 already described. At the second assembly 32 the material M is oriented in its direction of travel from horizontal to vertical, and it then enters a thermosol setting drum 33. The material M' is thereafter trained around a dip roll 34 in a rinsing bath 35 and past a drive roll 36 and around a dip roll 37 in a finish washing bath 38 adjoining the bath 35. The material M' thus cleaned is taken upwardly past the second drive roll 16 into the drier assembly D through a third-drying section D₃ and withdrawn via the third drive roll 17 for delivery as finished textile material. The drier assembly D is a single integral cylindrical drum construction capable of drying the textile material M and M' on passing through three respective guide apertures 39, 40 and 41 in the drum. The size of the aperture 40 in particular can be reduced to a minimum required for the particular yarn or tape to be treated, because of the arrangement of the orienting guide roll assembly 25 and 32 in which the guide rolls 27a - 27d are retractable from the path of travel of the material M' without causing the latter to deflect or jiggle which would otherwise occur to make the material M' to hit the edges of the aperture 40, resulting in color transfer or damage of the material M'. The material M treated in the process and apparatus of the invention above described is a fibrous polyester material in the form of a yarn or tape. When treating other materials such as rayon, nylon, acryl and the like fibers, the thermosol setting treatment may be effected with steam and there may be additionally provided surface coating on such dyed materials.

Claims: A process of dyeing an elongate textile material (M) with a variety of colours at predetermined intervals in a substantially continuous, uninterrupted cycle of operation, said process comprising the steps of: - depositing a dye on said textile material (M) to produce a dyed material (M'); orienting a direction of feed of said dyed material (M'); passing said dyed material (M') through a first section of a dryer assembly (D) to dry said dye; washing said dyed material (M'); rinsing said dyed material (M'); and drying said dyed material (M') by passing it through a second section of said dryer assembly (D); said process being characterised in that it further comprises the steps of (i) scouring the material (M), (ii) washing the material (M) and (iii) drying the material (M) by passing it through a third section of said dryer assembly (D) before the dye is deposited on said material; in that said textile material (M) is dyed at a single dye-depositing station (130); in that the process further comprises the steps of: - exchanging a dye bath (20a) containing a dye of one colour with another dye bath (20b) containing a dye of another colour at said dye depositing station (130); and simultaneously exchanging a nip roll (22a) and a guide roll (24a) with another nip roll (22b) and another guide roll (24b) respectively, said nip rolls (22a, 22b) and said guide rolls (24a, 24b) being mounted alternately on a rotatable support means (23); and it that the process further comprises the step of thermosol setting the dyed material (M') after the dyed material has passed through the second section of said dryer assembley (D). An apparatus (10) suitable for dyeing an elongate textile material (M) in a variety of colours at predetermined intervals in a substantially continuous, uninterrupted cycle of operation, said apparatus comprising: - means (130) for dyeing said textile material (M) to produce a dyed textile material; a dryer assembly (D) having first and second apertures (40, 41) for the passage of said dyed material (M'); and means (25) for orienting the direction of feed of the dyed textile material (M') so that said dyed textile material (M') passes through said first aperture (40) of said dryer assembly (D); said apparatus (10) being characterised in that said means (130) for dyeing said textile material comprises:- a single dye-depositing station (130); and at least two dye baths (20a, 20b), each of said dye baths (20a, 20b) being moveable towards and away from said dye-depositing station (130) whereby, in operation, a dye bath (20a) containing a dye of one colour can be exchanged with another dye bath (20b) containing a dye of another colour at said dye depositing station (130); in that said means (25) for orienting the direction of feed of the dyed textile material (M') comprises a first orienting guide roll assembly (25) including a support means (26) carrying around its periphery a plurality of spaced orienting rolls (27a - 27d), said support means (26) being rotatable to take one of said rolls (27a - 27d) out of engagement with said dyed material (M') and to bring another of said rolls (27a - 27d) into engagement with said dyed material (M'); in that said apparatus (10) further comprises a second orienting guide roll assembly (32) for re-orienting the direction of feed of the dyed material (M') after the dyed tape has passed through said dryer assembly (D), said second orienting guide roll assembly (32) being similar in structure and to said first orienting guide roll assembly (25); in that said dryer assembly (D) is in the form of a cylindrical drum; and in that said dryer assembly (D) comprises a third aperture (39), said undyed material (M) passing through said third aperture (39). An apparatus (10) according to Claim 2 in which said orienting rolls (27a - 27d) are each normally biased radially towards the axis of said support means (26). An apparatus (10) according to Claim 2 or 3 further including a polygonal cam plate (31) fixedly secured to a machine frame and adapted to retract one of said orienting rolls (27a - 27d) away from the path of the material (M') when said support means (26) rotates. An apparatus (10) according to Claim 4 in which said cam plate (31) has a cam surface (31b) extending substantially parallel with the path of the material (M') and another cam surface (31c) downwardly sloped to retract one of said rolls (27a - 27d) away from the path of the material (M').

Inventors: YOSHIDA, HIROSHI
Applicants: YOSHIDA KOGYO K.K.
Application year: 1989
Main classification: D06B11
IPC codes: D06B1, D06B23, D06B3, D06B11, D06B21