PROCESS AND APPARATUS FOR FORMULATING A TEXTILE FINISH

Abstract: A process and apparatus for treating an elongate textile substrate travelling longitudinally in a lengthwise direction having a mixing apparatus (10) with at least one interfacial surface generator (16) disposed in-line with the direction of travel of the textile substrate. Treatment components (12a, 12b) are conveyed into the mixing apparatus (10) and through the interfacial surface generator (16) for blending into a homogeneous mixture which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate. One or more pumps (114a, 114b) may be provided for conveying the treatment components. Heating means (228, 230) may be disposed in-line with the travelling substrate. Monitoring devices, such as mass flow meters (120), pressure gauges (121), and temperature sensors (122), as well as a programmable control unit (17) may also be included.

Description: PROCESS AND APPARATUS FOR FORMULATING A TEXTILE FINISH Background Of The Invention Field of the Invention The present invention generally relates to an in-line process for continuously preparing textile finish compositions and treating textiles therewith. More particularly, a process is provided whereby a predetermined amount of a textile finish composition having a specific formulation can be prepared on an as-needed basis for 10 treatment of textile materials. Finishing compositions are generally applied to textile fibers to improve their subsequent handling and processing. Fiber finishes play an important role in assisting the fiber producer to manufacture the product, and enable the fiber producer's customers to carry out the required yarn and fabric manufacturing processes to obtain the finished textile product. The composition and amount of fiber finish applied depend in large measure upon the nature, i.e., the chemical composition of the fiber, the particular stage in the processing of the fiber, and the end use under consideration. For example, compositions referred to as "spin finishes" are usually applied to textile fibers after extrusion. These or other finishes may be applied to yarn prior to knitting or winding, and to fiber tows prior to or at the time of crimping, drying, cutting, drawing, roving, and spinning, or to staple fibers prior to carding. The application of lubricants onto fibers prior to carding and subsequent textile operations such as yarn manufacture, preparation of nonwoven webs or processing of continuous filament yarns after the fiber spinning process are commonly called secondary or over-finishes. Such finishes provide lubrication, prevent static build-up, and afford sufficient cohesion between adjacent fibers. The application of such finishes is generally accomplished by contacting a fiber tow or yarn with a solution or an emulsion comprising at least one component having antistatic and/or lubricating properties. In addition to a lubricant and anti-static agent, additives such as wetting agents, antioxidants, biocides, anticorrosion agents, pH control agents, as well as emulsifiers are also commonly found in such finish mixtures. Finish compositions can also be applied to tow, yarn, or cut staple by spraying. Satisfactory finish compositions must fulfill a number of requirements in addition to providing desired lubricating and antistatic effects. For example, they should be easy to apply (and to remove if desired), they should have good thermal and chemical stability, they should not adversely affect the physical or chemical properties of the fibers to which they are applied and they should aid the subsequent processes to which the treated fibers are subjected, they should not leave residues on surfaces or cause toxic fumes or undesirable odors, they should provide for rapid wetting of fiber surfaces, they should be water-soluble or emulsifiable or solvent-soluble, they should have good storage stability, they should be compatible with sizes, non woven binders and other fiber treatments, they should not attract soil or cause color changes to the fibers, they should not interact with frictional elements used in texturizing and they should not be corrosive to machine parts. Discussion of Related Art Of the numerous compositions which have been proposed as fiber finishes, some of the more noteworthy may be found in the following prior art. For example, U.S. Patent 4,027,617 discloses a finish for acrylic fiber consisting of an alkyl phenol ethoxylated with 40 to 200 moles of ethylene oxide, an amine salt of hydrogenated tallow alcohol phosphate, and a mixture of mineral oil, an ethoxylated aliphatic monohydric alcohol, and the amine-neutralized reaction product of an ethoxylated aliphatic monohydric alcohol phosphate. In addition, U.S. Patent 3,997,450 relates to a finish composition for synthetic fibers such as polyamides and polyesters, consisting essentially of a lubricant selected from a mono- or diester of an aliphatic carboxylic acid with a monohydric aliphatic alcohol, or a refined mineral, animal or vegetable oil; an emulsifier containing up to so moles of alkylene oxide per mole of ester, alcohol, or amide wherein the reactive hydroxyl sites of the emulsifiers contain deactivating and cap groups; and an alkali salt of a dialkyl sulfosuccinic acid. Likewise, U.S. Patent 4,725,371 is directed to a finish for the texturing of partially oriented polyester yarn wherein the composition has a pH of at least 10, and comprises an oil-in-water emulsion wherein the oil phase constitutes 2 to 25 weight percent of the emulsion. The oil phase comprises a lubricant selected from mineral oils, alkyl esters, glycerides, silicone oils, waxes, paraffins, naphthenic and polyolefinic lubricants, glycols, glycol esters, and alkoxylated glycol esters. The emulsifiers employed include soaps, glycerol fatty acid esters, sorbitan and polyoxyethylene sorbitan esters, polyglycerol esters, polyoxyethylene esters or ethers, polyoxyethylene polyol ether esters, polyoxyethylene amines and amides, partial polyol ester ethoxylates, sulfated vegetable oils, sulfonated hydrocarbons, and the like. The purpose of a fiber finish is to provide fiber, to metal lubrication and fiber to fiber cohesion, as well as reduce static electricity. Although much of the basic work to elucidate the mechanisms of lubrication was done in the distant past, results of this work continue to be used to understand and apply results of frictional testing to current problems and the development of new finishes. The contribution of frictional and antistatic properties can be observed throughout fiber manufacturing and processing. An example is the case of a low denier polypropylene staple fiber which is to be carded into a web and thermally bonded for some disposable nonwoven application. This requires a formulation which in conjunction with the fiber crimp, contributes a relatively high fiber to fiber friction which is important in insuring a carded web with good cohesion, uniformity, and integrity, and which compensates for the low stiffness of the fibers. Low fiber to metal friction is also a key factor in the processing of these staple fibers which have diameters on the order of only 15 to 20 micrometers. Another example involves a slit film or ribbon type yarn intended for woven carpet backing for tufted carpets. During its manufacture, good wetting of the fiber surface by the finish and moderate frictional coefficients are required. For tufting, however, relatively low fiber to metal friction is a very important feature because of the action of tufting needles on the backing fabric. Finally, low fiber to fiber friction is a highly desirable feature of continuous filament yarns used in cordage applications which involve twisting and plying to form compact structures which have a large amount of fiber to fiber contact. Low friction is desirable since it is generally associated with high flex resistance, high energy absorption and therefore, long life. A different area of fiber-to-fiber friction is concerned with continuous filament yarns. This may be illustrated by some examples within the fiber manufacturing plant, i.e., package building in spinning and filament drawing or tow drawing are the major steps where the fiber-to-fiber friction is of critical importance. In yarn processing, yarn delivery in coning, stitch formation in knitting, filament damage in braiding, strength and elongation in cordage, slippage of weave in fabric, yarn-to-fabric friction in sewing, are some of the areas where yarn-to-yarn friction is important. Unfortunately, prior art finish compositions fail to provide adequate friction coefficients with respect to the bundle cohesion and scroop of synthetic fiber filaments. This lack of adequate bundle cohesion results in the following problems: migration of filaments from bundles in tri-color yams resulting in color streaking; difficulty in handling yams in a direct tuft carpet process in which yams are not twisted prior to tufting resulting in stray filaments being snagged; the filament twisting process is hindered due to the filaments separating from the main body of the fiber bundle; during fiber manufacture multiple wraps of the multifilament bundles are taken on various rolls wherein the bundles have a tendency to wander resulting in individual filaments from one bundle becoming trapped in an adjacent bundle causing a breakdown in the process. Finally, there is also a need in the industry to improve the seam slippage in synthetic fabrics, and particularly those made of polypropylene fibers. Textile finish compositions such as those described above are typically formulated by the end-user. Suppliers and manufacturers provide the end-user with the raw textile finish components needed to formulate the finish composition. Prior to their application onto textile substrates, the raw textiles finish components must first be formulated and/or diluted to a specific concentration for a particular application and/or mixed with auxiliary components such as emulsifiers, anti-static agents, etc.. A batchwise process is most commonly employed to formulate the textile finish compositions. This process involves introducing the raw textile finish components into a large vessel, and then mixing them with water along with any additional auxiliary components which may be required. The contents of the vessel are mixed by mechanical means such as by the use of a propeller-type mixing device or an auger. The disadvantages associated with the use of this type of batchwise process for formulating textile finish compositions are as follows. First, a significant amount of manpower must be expended in order to formulate the textile finish composition which involves weighing the amount of raw textile finish components, as well as any auxiliaries, to be employed in the particular textile finish being formulated, physically introducing the various components into a mixing container, inserting, supervising and subsequently cleaning the mechanical mixer employed, as well as other tasks involving the application of human effort. It is therefore an object of the present invention to provide a process which requires the expenditure of minimal manpower when emulsifying textile finish compositions prior to their application onto textile substrates. Secondly, due to the significant amount of manpower needed to prepare the textile finish composition prior to its application onto textile substrates, a particular textile finish composition must oftentimes be prepared in large quantities for future applications. Consequently, emulsifiers and biocides must be added to the textile finish composition to ensure that the emulsified finish neither separates nor becomes contaminated during storage. The addition of these preservative components adds significantly to the cost of making and using the textile finish compositions. It is therefore another object of the present invention to provide a process for preparing textile finish compositions which requires the addition of little, if any, preservative components. Further, even with the addition of emulsifiers and biocides to prolong shelf-life, these formulated textile finish emulsions have finite storage times so that if the formulated textile finish emulsion is not completely exhausted prior to the expiration of its shelf-life, any remainder must be disposed of, which in turn requires the additional expenditure of both manpower, the financial loss associated with any waste, as well as waste treatment and environmental concerns. It is therefore another object of the present invention to provide a process for preparing textile finish compositions on an as-needed basis and only in the particular amount needed for an application. Finally, an inordinate amount of floor space is required to accommodate the storage of both the raw textile finish components and any formulated textile finish composition which has not been completely exhausted. It is therefore a main object of the present invention is to provide a process for formulating textile finish compositions which can be prepared in-line with a particular textile substrate application process, and treating textile substrates therewith. Summary Of The Invention The present invention is generally directed to a process and apparatus for treating textile substrates which eliminates the need for the batchwise formulation of textile finish compositions prior to their application onto textile substrates. Fundamentally, the present invention provides a process and apparatus for treating an elongate textile substrate of indeterminant length wherein the textile substrate is caused to travel longitudinally in its lengthwise direction and a mixing apparatus having at least one interfacial surface generator is disposed in-line with the lengthwise direction of travel of the textile substrate. Simultaneously with the traveling movement of the textile substrate, a supply of a first textile treatment component and a supply of a second textile treatment component are conveyed into the mixing apparatus and through the interfacial surface generator, e.g. by means of suitable pumps or other conveying means, the first and second textile treatment components are blended within the interfacial surface generator into a homogeneous mixture which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate, and the blended finish composition is discharged from the mixing apparatus, e.g. by any suitable means, directly onto the traveling textile substrate substantially without intermediate storage of the finish composition for real¬ time surface finishing of the textile substrate along its traveling length. In most textile finishing applications utilizing the apparatus and method of the present invention, the textile treatment components will be immiscible with one another. For example, water may be utilized as one of the treatment components with the other textile treatment component being substantially insoluble in water. Advantageously, the present invention is effective for blending the first and second textile treatment components within the interfacial surface generator into a homogeneous emulsion which is substantially stable against separation of the immiscible components enabling the most optimal use thereof as a surface finish composition on the textile substrate. In preferred embodiments of the invention, a control unit is provided for automatically operating the mixing apparatus. For example, the control unit may be programmable to measure and introduce predetermined amounts of the first and second textile treatment components. In many applications, it is also advantageous to pre-heat one or both of the textile treatment components, e.g. by any suitable heating means, prior to the blending thereof in the interfacial surface generator. One or more pumps are preferably utilized to control the conveying of the textile treatment components into and through the mixing apparatus. In preferred embodiments, the pumps may be metering pumps, such as by way of example, progressive cavity metering pumps and gear metering pumps, and the heating means may be an electric heater disposed in-line with the lengthwise travel of the textile substrate. Preferably, the consistency of the blended finish composition and the pressure, temperature and rate of flow of the textile treatment components are monitored over the course of a textile finishing application. For example, at least one mass flow meter may be provided for measuring the flow rate of the first and second textile treatment components and at least one temperature sensor may be utilized for measuring the temperature of the first and second textile treatment components. For cleaning either periodically or when changing treatment components, the system may be equipped for selective operation to flush and clear the treatment components and the blended emulsion from the system. In a preferred embodiment, the process and apparatus of the present invention provides for the treatment of an elongate textile substrate of indeterminant length wherein the textile substrate is caused to travel longitudinally in its lengthwise direction and a mixing apparatus, which includes a first interfacial surface generator and a second interfacial surface generator, is disposed in-line with the lengthwise direction of travel of the textile substrate. Simultaneously with the traveling movement of the textile substrate, a supply of a first textile treatment component, a supply of a second textile treatment component and a supply of a third textile treatment component are conveyed into the mixing apparatus. In the preferred embodiment, at least one of the textile treatment components is water and at least one of the textile treatment components is substantially insoluble in water. Two of the textile treatment components are conveyed through the second interfacial surface generator and these components are blended within the second interfacial surface generator into a first homogeneous emulsion which is substantially stable against separation of the components. This first emulsion of the two textile treatment components and the other textile treatment component are conveyed through the first interfacial surface generator and blended into a second homogenous emulsion which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate. The blended finish composition is discharged from the mixing apparatus, e.g. by any suitable means, directly onto the traveling textile substrate substantially without intermediate storage of the finish composition for real-time surface finishing of the textile substrate along its traveling length. In addition, the preferred embodiment of the present invention may include a bypass means for conveying water through the mixing apparatus for cleaning either periodically or when changing treatment components. The process and apparatus of the preferred embodiment may also include additional means for discharging from the apparatus different blended finish compositions or emulsions directly onto the traveling textile substrate. The control unit for controlling operation of the mixing apparatus may include a control panel for programming the operation of the apparatus. The control unit is programmable to introduce the proportionate amounts of the first, second and third textile treatment components to be introduced into and the degree of blending performed by the first and second interfacial surface generators of the mixing apparatus. Further details, features and advantages of the invention can be understood from the exemplary embodiments described in the following description with reference to the accompanying drawings. Brief Description of the Drawings Figure 1 is a schematic view depicting the basic apparatus and method of the present invention for the in-line formulation of textile finish compositions, Figure 2 is a schematic view of one preferred embodiment of the in-line mixing apparatus and method of the present invention adapted for mixing two textile treatment components, e g. typically water and another component which is substantially immiscible in water; Figure 3 is a schematic view of the control unit for operating the apparatus; and Figure 4 is a schematic view of another preferred embodiment of the in-line mixing apparatus of the present invention adapted for mixing three textile treatment components. Detailed Description of the Preferred Embodiments Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about". The present invention provides for the in-line formulation of a textile finish composition on an as-needed basis, and its subsequent application onto a textile substrate. In accordance with the invention, water along with multiple raw textile finish components are fed into a mixing apparatus compπsing an interfacial surface generator wherein the components are intimately mixed in order to produce a formulated finish composition of predetermined quantity, concentration and characteπstics pπor to contact with a textile substrate. Turning now to the drawings and, more particularly to Fig. 1, the pπncipal components of a basic mixing apparatus 10 employed to carry out the method of the present invention include a water inlet port 12a and raw textile finish component inlet ports 12b and 12c for introducing water and raw textile finish components to be formulated into a textile finish composition, an interfacial surface generator 6 for statically mixing the water and raw textile finish components, an outlet port 19 for dispensing the formulated textile finish composition and a control unit 17 for controlling the operation of the apparatus 10. In operation, water is introduced to the apparatus from a source, not shown, through inlet port 12a. Raw textile finish components are similarly fed from individual sources, not shown, through inlet ports 12b and 12c. Valves 13a, 13b and 13c, are used to open and close inlet ports 12a, 12b and 12c so that water and the various raw textile finish components may be introduced into the interfacial surface generator 16 through fluid port 15. Due to the viscous state of the raw textile finish components employed, pumps 14a and 14b are used to meter the raw textile finish components through inlet ports 12b and 12c and they are combined, along with the water, into a single fluid stream and fed through fluid port 15 into the interfacial surface generator 16. The interfacial surface generator 16 employed in the present invention is well known in the art. For example, U.S. Patent 3,583,678, hereby incorporated by reference, discloses a typical interfacial surface generator used for static mixing of fluids wherein a fluid stream is divided into a plurality of substreams which are then recombined, divided, repositioned, and recombined again until a desired degree of mixing is obtained. These types of interfacial surface generators are capable of providing a degree of mixing that is a function of the number of static mixing elements (n) employed. Each element individually divides and mixes the liquid stream four times. Consequently, each additional element (n) employed increases the degree of mixing on the order of 4 other examples of interfacial surface generators known in the art, and also incorporated herein by reference, are disclosed in U.S. Patent 3,358,749, 3,404,869 and 3,652,061. Once the water and raw textile finish components are sufficiently mixed to formulate a particular textile finish composition, valve 18 is opened so that the textile finish composition may be discharged through outlet port 19. The freshly formulated textile finish composition is then ready for contact with a textile substrate. While the apparatus 10 can be operated manually with the use of a minimal amount of manpower with respect to the opening and closing of valves 13a, 13b, 13c and 18, as well as the actuation of pumps 14a and 14b, along with the interfacial surface generator 16, it is preferred that a control unit 17 be employed in operative connection with the apparatus to perform all of these functions. The type of control unit 17 employed by the present invention is well known in the art. The control unit 17 is capable of being programmed so that predetermined amounts of water and various raw textile finish components may be measured and subsequently introduced into the interfacial surface generator 16. Similarly, the control unit 17 can also be programmed to provide varying degrees of mixing for numerous types of textile finish compositions. Thus, according to the first preferred embodiment of the present invention, all of the operating components of the apparatus 10 are electronically controlled, with variables such as amounts of water and raw textile finish components to be admixed and degrees of mixing being programmed into and controlled by control unit 17. The primary components of most textile finish compositions include a lubricant, emulsifiers known in the art such as ethoxylated C 12-18 fatty alcohols, an anti-jelling agent and an anti-static agent. It is oftentimes highly desirable to also include a wetting agent to aid in the penetration, spread and adherence of the textile finish composition onto the textile substrate. The textile composition is typically applied onto the textile substrate as an aqueous emulsion. The lubricant component of the fiber finish composition is preferably selected from the group consisting of ethoxylated fatty acids such as the reaction product of ethylene oxide with pelargonic acid to form PEG 300 monopelargonate (Emerest ® 2634) and PEG 400 monopelargonate (Emerest ® 2654), the reaction product of ethylene oxide with coconut fatty acids to form PEG 400 monolaurate (cocoate) (Emerest ® 2650) and PEG 600 monolaurate (Emerest ® 2661), and the like. The lubricant component can also be selected from non-water-soluble materials such as synthetic hydrocarbon oils, alkyl esters such as tridecyl stearate (Emerest ® 2308) which is the reaction product of tridecyl alcohol and stearic acid, and polyol esters such as trimethylol propane tripelargonate (Emery ® 6701) and pentaerythritol tetrapelargonate (Emery ® 2484), as well as oxa-acid esters, may also be employed. In general, however, any lubricant based on synthetic, mineral, animal or vegetable oil typically known in the art for use as a lubricant in textile finish compositions may be employed in the present invention. The textile finish of the present invention is emulsifiable and capable of forming a stable emulsion with water. By the term "stable emulsion" it is meant that the emulsion is stable at the time of application of the textile finish composition to a textile substrate. This is meant to include both oil-in-water and water-in-oil finishes which, typically, are mixed well prior to their application and then applied via various applicators from a storage tank or the like and thus the textile finish composition in the form of an emulsion must traditionally be stable for extended time periods. However, by employing the present process, textile finish compositions in the form of a highly dispersed emulsion can be prepared in the exact amount needed for a particular application, in-line with the application process, and on an as-needed basis. The present process reduces the concentration of emulsifier required to maintain a stable emulsion. Hence, since less emulsifier is needed, this translates into a significant savings in production costs. Anti-static agents function by either reducing the charge generation or by increasing the rate of charge dissipation. Most antistats operate by increasing the rate of dissipation and rely on atmospheric moisture for their effectiveness. A hydrophobic fiber such as polypropylene depends on an antistat coating to impart high surface conductivity for charge dissipation. The antistatic agent may comprise any suitable anionic, cationic, amphoteric or nonionic antistatic agent. Anionic antistatic agents are generally sulfates or phosphates such as the phosphate esters of alcohols or ethoxylated alcohols. Cationic antistatic agents are typified by the quaternary ammonium compounds and imidazolines which possess a positive charge. Examples of nonionics include the polyoxyalkylene derivatives. The anionic and cationic materials tend to be more effective antistats. Preferred anionic antistatic agents for use herein include an alkali metal salt, e.g., potassium, of a phosphate ester such as commercially available from Henkel Corporation, Mauldin, South Carolina, under the tradenames Tryfac ® 5559 or Tryfac ® 5576. Preferred nonionic antistatic agents include ethoxylated fatty acids (Emerest' 2650, an ethoxylated fatty acid), ethoxylated fatty alcohols (Trycol ® 5964, an ethoxylated lauryl alcohol), ethoxylated fatty amines (Trymeen ® 6606, an ethoxylated tallow amine), and alkanolamides (Emid ® 6545, an oleic diethanolamine). Such products are commercially available from Henkel Corporation, Mauldin, South Carolina. The amount of antistatic agent present in the finish composition is generally from about 5 to about 30 weight percent when there is a possibility that static electricity may be a problem. In some cases less might be required, for example, for continuous filament ya s which are interlaced or for a winding operation. In other cases such as for staple fiber processing, larger amounts of antistatic agent may be required. The satisfactory application of the various textile finish compositions oftentimes requires that a surfactant and/or a solvent be used as a wetting agent in the composition. The surfactant and/or solvent acts to ensure that the particular textile finish composition to which it is added is evenly and effectively distributed throughout the textile substrate. While the use of wetting agents in textile finish compositions is well known in the art, a particularly preferred wetting agent is an alkylpolyglycoside of formula I R 1 O(Z) a (I) wherein R 1 is a monovalent organic radical having from about 6 to about 30 carbon atoms; Z is a saccharide residue having 5 or 6 carbon atoms; and a is a number having a value from 1 to about 6. The textile finish composition may be applied onto a textile substrate according to a variety of known procedures. For example, in the melt spinning process used for polypropylene manufacture, the polymer is melted and extruded through spinnerette holes into filaments which are cooled and solidified in an air stream or water bath. Shortly after, the filaments contact a textile finish composition applicator which can be in the form of a kiss roll rotating in a trough. The amount of active finish composition applied to the filaments can be controlled by the concentration of textile finish composition in the solution or emulsion and the total wet pick-up. Alternatively, positive metering systems may be used which pump the finish composition to a ceramic slot which allows the finish composition to contact the moving filaments. Textile finish compositions can also be applied onto textile substrates by spraying. From this point, the textile substrate which now has a coating of textile finish composition moves forward into any of several processes. The amount of finish composition to be applied onto a synthetic filament is also dependent on the end product of the filament yam. If staple fiber is the desired product, the filament bundles are combined into large tows, oriented by stretching, crimped, and cut into short lengths for processing on textile equipment to ultimately make yam or nonwoven webs. In a preferred embodiment of the present invention, the present process is employed to formulate spin finish emulsions, in-line with a textile substrate application process, on an as-needed basis. The primary components of a spin finish are a lubricant, an emulsifier, an anti-static agent and water which, when combined, form an emulsion. Predetermined amounts of these components are combined and mixed so as to formulate a spin finish composition having a specific concentration required for an end-user's particular application process. Varying concentrations of spin finishes in turn require varying degrees of mixing so that a desired degree of dispersion of the raw textile finish components and water is obtained. Thus, referring again to Fig. 1, specific parameters relating to both the amounts of water and raw textile finish components to be mixed, along with the degree of mixing to be performed, are programmed into the control unit 17. It should be noted that in this particular embodiment, a wetting agent is also being employed. Valves 13a, 13b and 13c are opened, and pumps 14a and 14b actuated, so that predetermined amounts of water via inlet port 12a, lubricant component via conduit 12b and wetting agent via conduit 12c are introduced into the interfacial surface generator 16 in a single stream through fluid port 15. The interfacial surface generator then statically mixes the programmed amounts of water and raw textile finish components to a predetermined degree of dispersion, thus formulating the spin finish. Once the spin finish composition is formulated, valve 18 is opened and the newly formulated spin finish composition is discharged through outlet port 19. The spin finish composition is then contacted with a textile substrate. It is thus clear that by employing the process and apparatus of the present invention, thoroughly mixed and precise formulations of textile finish compositions can be formulated in-line with a textile substrate treating process, on an as-needed basis. The apparatus 10 is capable of being employed in-line with any textile treating process. Moreover, since only the precise amount of textile finish composition that is required for any one textile application process is formulated at any one time, the need for employing auxiliaries such as emulsifying agents to maintain the emulsion or biocides to preserve the formulated textile finish composition are reduced or eliminated. Also, waste associated with both the space required to store textile finish compositions when an excess amount is formulated and the expiration of the composition's shelf-life is similarly avoided by employing the present process. Similarly, the amount of manpower required by the present process is substantially less than that of conventional formulating processes. The newly formulated textile finish compositions may be applied to virtually any textile substrate including glass, cellulosics such as acetate, triacetate, rayon, non-cellulosics such as acrylics, modacrylic, nylon, aramid, olefins such as polyethylene and polypropylene, polybenzimidazole, polyesters such as polyethylene terephthalate and polybutylene terephthalate or copolyesters thereof, saran, spandex and vinyon. It should be noted that although only two textile finish components are shown in the basic mixing apparatus as being combined and mixed with water to formulate a textile finish composition, any number of raw textile finish components or auxiliaries such as surfactant blends/dispersions of waxy lubricants, for example fatty amides, fatty esters, oxidized polyethylene, and the like, needed for a particular textile finish composition may be employed. The basic process and apparatus of the present invention will be better understood from the examples which follow, all of which are intended to be illustrative only and not meant to unduly limit the scope of the invention. Unless otherwise indicated, percentages are on a weight-by-weight basis. Example I A spin finish composition for fiber and textile applications was prepared having the following formulation. Component % by weight (a) STANTEX ® 1910-G 10 (b) water 90 (a) STANTEX' 1910-G, a nonionic fiber finish available from Henkel Corporation, Textiles Group, Charlotte, North Carolina, is a blend of sulfated glycerides, mineral oil, esters and ethoxylated fatty alcohols. The components listed above were introduced, in a single stream, into an interfacial surface generator, at ambient temperature, and then mixed to form an aqueous spin finish emulsion. Comparative Example I A spin finish composition for fiber and textile applications was prepared having the following formulation: Component % by weight (a) STANTEX ® 1910-G 10 (b) water 90 The components listed above were mixed, at a temperature of 50°C, using conventional agitation to form a spin finish. The textile spin finish compositions of Example 1 and Comparative Example 1 were then analyzed to determine their aesthetic appearance and degree of mixing. A photoelectric colorimeter, clinical model, catalog number 76-500-000, available from MANOSTAT ® Inc., 519 Eighth Ave., New York, NY was used to measure the degree of mixing achieved by the present process versus a conventional mixing process. Table I summarizes the results obtained. The data in Table 1 shows that by employing the present process of mixing textile and spin finishes, a significantly increased degree of mixing is obtained, as compared to conventional mixing techniques. Moreover, due to the significantly enhanced degree of mixing obtained with limited expenditure of manpower, as compared to conventional mixing processes, the present process allows for the in-line mixing of textile and spin finishes on an as-needed basis. One advantageous use of the present process and apparatus is for mixing long molecule products. While it may be desirable to include these agents to eliminate sling-off, long molecule products heretofore have been extremely difficult to mix. The present invention allows for easily mixing long molecule products and formulation of optimal textile finish compositions. One preferred embodiment of the process and apparatus for the in-line formulation of a textile finish composition is shown in Fig. 2 and designated generally by the numeral 110. While the illustrated first textile treatment component is water and the second textile treatment component is a raw textile finish component, the textile treatment components of the present invention may include water, a lubricant, an anti¬ static agent, a wetting agent, an emulsifier, an anti-jelling agent and mixtures thereof or any suitable textile treatment component. The apparatus 110 of the preferred embodiment includes a water inlet port 112a and a raw textile finish component inlet port 112b for introducing water and raw textile finish component into the apparatus, an interfacial surface generatorl lό for statically mixing the water and raw textile finish component, an outlet port 119 for dispensing the formulated textile finish composition and a control unit (not shown) for controlling the operation of the apparatus 110. As shown in Fig. 2, the apparatus 110 includes mass flow meters 120, pressure gauges 121 and temperature sensors 122 for measuring the flow, pressure and temperature of the water and textile finish component which are being conveyed into the apparatus 110 by pumps 114a and 114b. The apparatus 110 further includes heaters 128,130 which are positioned in-line to heat the water and textile finish component before each enters the interfacial surface generator 116. Each heater 128,130 is an in-line electric heater as is known in the industry. In addition, the apparatus 110 includes a flush outlet port 129 for flushing an emulsion from the system. In operation, water is pumped by the water pump 114b into the apparatus 110 while the raw textile finish component is pumped by the oil pump 114a. As the water and raw textile finish component are pumped through the line, the temperature sensors 122 and mass flow meters and pressure gauges 120,121 measure the flow rate, pressure and temperature of each. As the components approach the interfacial surface generator 116, the water and raw textile finish component are combined into a single fluid stream and fed through the fluid port 115 into the interfacial surface generator 116. The interfacial surface generator 116 of the preferred embodiment mixes the components into a homogeneous mixture until a desired degree of blending is obtained. After the textile finish composition is formulated, it may be discharged through the outlet port 119. Alternatively, the textile finish composition may be flushed from the system through the flush outlet port 129. Fig. 3 illustrates the various electronically controlled functions performed by the control unit 117 which is in operative connection with the apparatus 110. The control unit 117 is programmable and includes a control panel 132. In the preferred embodiments, the control unit 117 is programmed to control the run time and speed of the water pump 114b and the oil pump 114a so that predetermined amounts of water and raw textile finish component may be measured and introduced into the mixing apparatus 110. The control unit may also electronically control the operation of the valves throughout the apparatus and the temperature settings of the heaters 128,130. As shown in Fig. 3, the control unit 117 receives and processes information from the various monitoring devices, including the mass flow rate meters and pressure gauges 120,121 and temperature sensors 122 which deliver the flow rate, pressure and temperature of the water and raw textile finish component at various points during the process. Thus, the control unit 117 is adapted to receive information from the monitoring devices, including the pressure of the components as they enter the interfacial surface generator 116 and the consistency and temperature of the emulsion discharged from the interfacial surface generator, for optimally controlling the operation of the apparatus. Another preferred embodiment of the process and apparatus of the present invention is shown in Fig. 4 and designated generally by the numeral 210. The apparatus 210 is adapted to receive a supply of a first textile treatment component, a second textile treatment component and a third textile treatment component of which at least one is substantially insoluble in water. Figure 4 illustrates one scenario in which water is being utilized as the first textile treatment component and the second and third textile treatment components are raw textile finish components. The apparatus 210 includes a water inlet port 212c and two raw textile finish component ports 212a and 212b and pumps 214a,214b,214c for conveying the water and components through the apparatus. Heaters 228,230 are provided for heating the water and at least one of the raw textile finish components prior to blending the components. Mass flow meters 220, pressure gauges 221 and temperature sensors 222 are also provided for monitoring the flow rate, pressure and temperature of the components as they proceed through the process. As in the first preferred embodiment and as schematically illustrated in Fig. 3, a control unit (not shown) is provided for automatically operating the mixing apparatus. The preferred control unit is programmable to measure and introduce predetermined amounts of the first, second and third textile treatment components into the mixing apparatus and to provide varying degrees of blending the components within the first and second interfacial surface generator. As shown in Fig. 4, this preferred embodiment of the present invention includes a first interfacial surface generator 216 and a second interfacial surface generator 234. In operation, the two raw textile finish components are pumped into the mixing apparatus 210 and into the second interfacial surface generator 234 where they are blended into a first homogeneous emulsion. The first emulsion which is discharged from the second interfacial generator 234 and the water are combined into a single stream in fluid port 215 and introduced into the first interfacial surface generator 216. The blended finish composition is discharged through a first outlet port 219. The apparatus 210 also includes a second outlet port 227 for discharging a second blended finish composition and a flush outlet port 229 for clearing the system of an emulsion. In addition, the preferred embodiment includes a bypass means for conveying only water through the mixing apparatus for cleaning the system. As shown in Fig. 4, the bypass means may include a bypass line 236 extending from a line conveying water through the apparatus to a line conveying a raw textile finish component. Thus, the water pumped into the apparatus 210 by water pump 214c may be selectively diverted through the bypass line 236 to flush and clear the treatment components and the blended emulsions from the system. It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.

Claims: WHAT IS CLAIMED IS: 1. A process for treating an elongate textile substrate of indeterminant length, comprising: (a) causing the textile substrate to travel longitudinally in its lengthwise direction; (b) providing a mixing apparatus including an interfacial surface generator disposed in-line with the lengthwise direction of travel of the textile substrate; and (c) simultaneously with the traveling movement of the textile substrate: (i) conveying a supply of a first textile treatment component and a supply of a second textile treatment component into the mixing apparatus and through the interfacial surface generator; (ii) blending the first and second textile treatment components within the interfacial surface generator into a homogeneous mixture which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate; and (iii) discharging the blended finish composition from the mixing apparatus directly onto the traveling textile substrate substantially without intermediate storage of the finish composition for real-time surface finishing of the textile substrate along its traveling length. 2. The process of claim 1, wherein the mixing apparatus includes a second interfacial surface generator and further comprises, prior to the step of conveying a supply of at least one second component, the steps of: a. conveying the supply of the second textile treatment component and a supply of a third textile treatment component into the mixing apparatus and through the second interfacial surface generator; b. blending the second textile treatment component and the third textile treatment component within the second interfacial surface generator into a homogeneous mixture which is substantially stable against separation of the second and third textile treatment components; and c. conveying the blended mixture of the second and third textile treatment components through the first-mentioned interfacial surface generator for blending with the first textile treatment component. 3. The process of claim 1, wherein one of the first and second textile treatment components is water and the other textile treatment component is a textile finish component. 4. The process of claim 3, wherein the other textile treatment component is substantially insoluble in water and wherein the blending step produces a homogeneous emulsion thereof. 5. The process of claim 1 , wherein one of the first and second textile treatment components is a first textile finish component and the other textile treatment component is a second textile finish component. 6. The process of claim 2, wherein one of the first, second and third textile treatment components is water and another thereof is a textile finish component. 7. The process of claim 6, wherein one of the first, second and third textile treatment components is substantially insoluble in water and wherein the blending steps produce a homogeneous emulsion of the first, second and third textile treatment components. 8. The process of claim 1, further comprising the step of heating at least one of the first and second textile treatment components prior to blending thereof in the interfacial surface generator. 9. The process of claim 1 , further comprising the step of selectively conveying only the water through the mixing apparatus for cleaning thereof. 10. The process of claim 1, further comprising the step of monitoring the consistency of the blended finish composition. 11. The process of claim 10, further comprising the step of monitoring the pressure, temperature and rate of flow of the first textile treatment component and the second textile treatment component. 12. The process of claim 1 , further comprising the step of transporting the textile substrate coated with the blended finish composition to subsequent processing steps without removing the surface finish composition. 13. The process of claim 1, further comprising the step of providing a control unit for automatically operating the mixing apparatus including the interfacial surface generator. 14. The process of claim 13, further comprising the step of programming the control unit to measure and introduce predetermined amounts of the first textile treatment component and the second textile treatment component into the interfacial surface generator. 15. The process of claim 13, further comprising the step of programming the control unit to provide varying degrees of blending the first and second textile treatment components within the interfacial surface generator. 16. The process of claim 1, wherein the textile substrate is a strand. 17. The process of claim 3, wherein the textile finish component is selected from a lubricant, an anti-static agent, a wetting agent, an emulsifier, an anti- jelling agent and mixtures thereof. 18. The process of claim 1, wherein the blending step comprises a degree of mixing of about 4s, wherein n represents a number of mixing elements contained in the interfacial surface generator. 19. The process of claim 3, wherein the textile finish component is free of an emulsifier. 20. The process of claim 3, wherein the textile finish component is free of a preservative. 21. The process of claim 3, wherein the textile finish component is free of a laundering detergent. 22. The process of claim 17, wherein the lubricant is selected from the group consisting of ethoxylated fatty acids having a chain length ranging from about 9 to 18 carbon atoms, butyl stearate, tridecyl stearate, polyol esters, synthetic hydrocarbon oils, mineral oils, animal oils, vegetable oils, oxa-acid esters and mixtures thereof. 23. The process of claim 17, wherein the anti-static agent is selected from the group consisting of an amine nuetralized phosphate ester, quaternary ammonium salts, alkali neutralized phosphate ester, imidazolines, alkali sulfates, ethoxylated fatty acids, ethoxylated fatty amines, ethoxylated alcohols, alkanolamides, and mixtures thereof. 24. A process for treating an elongate textile substrate of indeterminant length, comprising: (a) causing the textile substrate to travel longitudinally in its lengthwise direction; (b) providing a mixing apparatus disposed in-line with the lengthwise direction of travel of the textile substrate, the mixing apparatus including a first interfacial surface generator and a second interfacial surface generator; and (c) simultaneously with the traveling movement of the textile substrate: (i) conveying a supply of a first textile treatment component, a supply of a second textile treatment component and a supply of a third textile treatment component into the mixing apparatus, at least one of the textile treatment components comprising water and at least one of the textile treatment components being substantially insoluble in water; (ii) conveying two of the textile treatment components through the second interfacial surface generator; (iii) blending the two textile treatment components within the second interfacial surface generator into a first homogeneous emulsion which is substantially stable against separation of the components; (iv) conveying the first emulsion of textile treatment components and the other textile treatment component through the first interfacial surface generator; (v) blending the other textile treatment component and the first blended emulsion of textile treatment components within the first interfacial surface generator into a second homogenous emulsion which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate; and (vi) discharging the blended finish composition from the mixing apparatus directly onto the traveling textile substrate substantially without intermediate storage of the finish composition for real-time surface finishing of the textile substrate along its traveling length. 25. A process for formulating a textile finish composition for real-time surface application onto an elongate textile substrate of indeterminant length traveling longitudinally in its lengthwise direction, comprising: (a) providing a mixing apparatus including an interfacial surface generator; (b) conveying a supply of a first textile treatment component and a supply of a second textile treatment component through the interfacial generator; (c) blending the first and second textile treatment components within the interfacial surface generator into a homogenous mixture which is substantially stable against separation of the components and is capable of use as a surface finish on the textile substrate; and (d) discharging the blended finish composition from the mixing apparatus. 26. The process of claim 25, wherein one of the first and second textile treatment components is water and the other textile treatment component is a textile finish component. 27. The process of claim 26, wherein the other textile treatment is substantially insoluble in water and wherein the blending step produces a homogeneous emulsion thereof. 28. The process of claim 25, further comprising the step of heating at least one of the first and second textile treatment components prior to blending thereof in the interfacial surface generator. 29. The process of claim 25, further comprising the step of selectively conveying only the water through the mixing apparatus for cleaning thereof. 30. The process of claim 25, further comprising the step of monitoring the consistency of the blended finish composition. 31. The process of claim 30, further comprising the step of monitoring the pressure, temperature and rate of flow of the first textile treatment component and the second textile treatment component. 32. The process of claim 25, further comprising the step of providing a control unit for automatically operating the system including the interfacial surface generator. 33. The process of claim 32, further comprising the step of programming the control unit to measure and introduce predetermined amounts of the first textile treatment component and the second textile treatment component into the interfacial surface generator. 34. The process of claim 32, further comprising the step of programming the control unit to provide varying degrees of blending the first and second textile treatment components within the interfacial surface generator. 35. The process of claim 25, wherein the textile finish component is selected from a lubricant, an anti-static agent, a wetting agent, an emulsifier, an anti- jelling agent and mixtures thereof. 36. The process of claim 25, wherein the blending step comprises a degree of mixing about 4a, wherein n represents a number of mixing elements contained in the interfacial surface generator. 37. The process of claim 25, wherein the textile finish component is free of an emulsifier. 38. The process of claim 25, wherein the textile finish component is free of a preservative. 39. The process of claim 25, wherein the textile finish component is free of a laundering detergent. 40. The process of claim 35, wherein the lubricant is selected from the group consisting of ethoxylated fatty acids having a chain length ranging from about 9 to 18 carbon atoms, butyl stearate, tridecyl stearate, polyol esters, synthetic hydrocarbon oils, mineral oils, animal oils, vegetable oils, oxa-acid esters and mixtures thereof. 41. The process of claim 35, wherein the anti-static agent is selected from the group consisting of an amine nuetralized phosphate ester, quaternary ammonium salts, alkali neutralized phosphate ester, imidazolines, alkali sulfates, ethoxylated fatty acids, ethoxylated fatty amines, ethoxylated alcohols, alkanolamides, and mixtures thereof. 42. Apparatus for treating an elongate textile substrate of indeterminant length while the textile substrate is traveling longitudinally in its lengthwise direction, the apparatus comprising; (a) a mixing apparatus including an interfacial surface generator disposed in-line with the lengthwise direction of travel of the textile substrate; (b) means operative simultaneously with the traveling movement of the textile strand for conveying a supply of a first textile treatment component and a supply of a second textile treatment component into the mixing apparatus and through the interfacial surface generator for blending the first and second textile treatment components within the interfacial surface generator into a homogeneous mixture which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate; and (c) means for discharging the blended finish composition from the mixing apparatus directly onto the traveling textile strand substantially without intermediate storage of the finish composition for real-time surface finishing of the textile substrate along its traveling length. 43. The apparatus of claim 42, wherein the mixing apparatus includes a second interfacial surface generator for blending the second textile treatment component and a third textile treatment component within the second interfacial surface generator into a homogeneous mixture. 44. The apparatus of claim 42, wherein one of the first and second textile treatment components is water and the other textile treatment component is a textile finish component. 45. The apparatus of claim 44, wherein the other textile treatment component is substantially insoluble in water and wherein the blending thereof produces a homogenous emulsion. 46. The apparatus of claim 42, wherein one of the first and second textile treatment components is a first textile finish component and the other textile treatment component is a second textile finish component. 47. The apparatus of claim 43, wherein one of the first, second and third textile treatment components is water and another thereof is a textile finish component. 48. The apparatus of claim 47, wherein one of the first, second and third textile treatment components is substantially insoluble in water and wherein the blending thereof produces a homogenous emulsion of the first, second and third textile treatment components. 49. The apparatus of claim 42, further comprising means for heating at least one of the first and second textile treatment components operative prior to the blending thereof. 50. The apparatus of claim 42, wherein the conveying means comprises at least one pump for conveying the first and second textile treatment components into and through the mixing apparatus. 51. The apparatus of claim 50, further comprising at least one mass flow meter for measuring flow rate of the first and second textile treatment components. 52. The apparatus of claim 50, further comprising at least one temperature sensor for measuring temperature of the first and second textile treatment components. 53. The apparatus of claim 44, wherein said conveying means comprises bypass means for conveying only water through the mixing apparatus for cleaning thereof. 54. The apparatus of claim 42, further comprising a control unit for controlling operation of the mixing apparatus. 55. The apparatus of claim 54, wherein the control unit includes a control panel for programming operation of the apparatus. 56. The apparatus of claim 54, wherein the control unit is adapted for programming the proportionate amounts of the first and second textile treatment components to be introduced into the interfacial surface generator. 57. The apparatus of claim 54, wherein the control unit is adapted for programming the degree of blending performed by the interfacial surface generator. 58. Apparatus for treating an elongate textile substrate of indeterminant length while the textile susbtrate is traveling longitudinally in its lengthwise direction, the apparatus comprising; (a) a mixing apparatus disposed in-line with the lengthwise direction of travel of the textile substrate, the mixing apparatus including a first interfacial surface generator and a second interfacial generator; (b) a first means for conveying a supply of a first textile treatment component, a supply of a second textile treatment component and a supply of a third textile treatment component into the mixing apparatus wherein at least one of the textile treatment components comprises water and at least one of the textile treatment components being substantially insoluble in water for blending two textile treatment components within the second interfacial surface generator into a first homogeneous emulsion which is substantially stable against separation of the components; (c) a second means operative simultaneously with the traveling movement of the textile substrate for conveying the first emulsion and the other textile treatment component through the first interfacial surface generator for blending the other textile treatment component and the first emulsion of textile treatment components within the first interfacial surface generator into a second homogeneous emulsion which is substantially stable against separation of the components and is capable of use as a surface finish composition on the textile substrate; and (d) means for discharging the blended finish composition from the mixing apparatus directly onto the traveling textile substrate substantially without intermediate storage of the finish composition for real-time surface finishing of the textile substrate along its traveling length. 59. Apparatus for formulating a textile finish composition for real-time surface application onto an elongate textile substrate of indeterminant length traveling longitudinally in its lengthwise direction comprising: (a) a mixing apparatus disposed in-line with the lengthwise direction of the travel of the textile substrate, the mixing apparatus including an interfacial surface generator; (b) means for conveying a supply of a first textile treatment component and a supply of a second textile treatment component into the mixing apparatus and through the interfacial surface generator for blending the first and second textile treatment components within the interfacial surface generator into a homogeneous mixture which is substantially stable against separation of the components and is capable of use as a surface finish on the textile substrate; and (c) means for discharging the blending finish composition from the mixing apparatus. 60. The formulating apparatus of claim 59, further comprising means for heating at least one of the first and second textile treatment components. 61. The formulating apparatus of claim 59, wherein said conveying means comprises a plurality of control valves. 62. The formulating apparatus of claim 59, wherein said conveying means comprises bypass means for conveying only water through the mixing apparatus for cleaning thereof.

Inventors: ANDERSON JACK L, ANDERSON, JACK, L.
Applicants: HENKEL CORP, HENKEL CORPORATION
Application year: 1999
Main classification: B05C3
IPC codes: D06B23