PROCESS FOR THE PREPARATION OF INDIGO DYED YARN FOR USE IN THE MANUFACTURE OF KNITTED FABRIC

Abstract: A process for the preparation of indigo dyed yarn for use in the manufacture of knitted fabric by a knitting machine comprising in the steps of, forming a dyed rope of yarn by the steps of indigo dyeing; individualizing the yarn of said dyed rope; forming separate packages of the yarn on separate spools of fixed ends; preparing individual hanks of each yarn end of each spool by hank maker; converting said hanks into individual cones of single yarn.

Description: TITLE PROCESS FOR THE PREPARATION OF INDIGO DYED YARN FOR USE IN THE MANUFACTURE OF KNITTED FABRIC FIELD OF IT ENTTON This invention relates to a novel process for the preparation of indigo dyed yarn for use in the manufacture of knitted fabric. PRIOR ART The process of indigo dyeing is known as such in the art. Tn the known process, the dyeing of yarn is continuous only on the surface because of oxidation during the process. In such a process, the core of the yarn remains undyed and is always in its natural shade. Such a process of indigo dyeing is performed at room temperature and under atmospheric pressure. The yarn is dyed in the form of a rope containing 240-400 ends throughout its length and is dyed by using a rope dyeing macliine. For this purpose, the rope is first subjected to the process of scouring at a temperature of 75 to 85°C and then subjected to the successive steps of hot and cold wash. The washed yarn is then passed through a plurality of dye baths, the number of dye baths being dependent on the colour and the shade. Finally, the yarn is subjected to the step of hot washing at 60-70°C followed by cold wash at room temperature and then to the step of softening. As will be apparent, the process employs an open bath system and yarn is subjected to air oxidation, which is required for surface dyeing of the yarn. The rope with 240-400 ends and which is subjected to such a step of dyeing is prepared by a warping machine. The dyed rope obtained after the process of dyeing is delivered into a can capable of accommodating upto 100 kgs, of rope. The dyed rope with the required ends is then fed to a long chain beamer to convert the rope into a warper beam and then subjected to the step of sizing to impart strength so as to withstand friction during weaving of cloth on a loom. However, prior to the step of sizing, each end of yam is individualized and then wound onto a beam widthwise. The process described hereinabove was advantageously employed in the weaving of a fabric in a loom, but could not be employed in a knitting machine for producing a knitted fabric. OBJECTS OF THE INVENTION A primary object of this invention is to propose a process for the preparation of indigo dyed yam for use in the manufacture of knitted fabrics. Another object of this invention is to propose a process for the preparation of indigo dyed yam in the form of cone where the yam is received in fixed numbers of ends from the dyed rope of 216 ends. On 6 individuals spools fitted on the shaft and thus avoiding the use of Warper Beam. Yet another object of this invention is to propose a process for the preparation of indigo dyed yam in the form of cone for use in the manufacture of knitted fabric as intermediate or individual spool used for shifting the yam from Warper Beam, cannot be fed directly to knitting machines to knit the fabric and thus avoiding use of intermediate spools and individuals spools, A further object of this invention is to propose a system for preparation of dyed indigo yam for manufacture of knitted fabrics. So far the process in existence was suitable for weaving i.e. for manufacturing cloth only. Reason is that yam used to be received on Warper Beamer having 3600 ends to 4000 ends cannot be used on a knitting machine, FIELD OF INVENTION According to this invention, there is provided a process for the preparation of indigo dyed yam for use in the manufacture of knitted fabric comprising receiving a dyed yam from a dyed rope, individualizing the yams forming said rope, receiving a sheet of said yams on its respective spool and such that the yams from said rope are collected as a plurality of individual length of ya on its respective spool, preparing individual hanks from the respective individual ends of yam of the spool, converting said hank into a cone of single yam by hank to cone maker. The process for the preparation of indigo dyed yam according to a preferred embodiment of this invention is herein described in detail in the following description. Tn accordance with the present invention, a dyed rope is prepared in a manner known as such in the art. In the known process, the dyed rope is fed to a long chain beamer to form a warper beam. Such a warper beam could be employed only in the process of weaving a fabric and not for producing a knitted fabric. In distinction to the known art, the dyed ya from a dyed rope is received directly on a plurality of spools, such as a set of six spools, instead of a warper beam in the conventional process. The spools are mounted on a warper beam shaft driven by a friction drum which is driven by a motor independently. Each spool receives, for example, 36 ends through warper comb and separator. The machine has a rope vibrator to open the rope into individual yam and a stop motion device so as to stop the machine in the event of a missing or broken yam. Six spools of 36 ends are produced at a time with, for example, 12-13 kgs. of weight of yam in each spool. The spools are mounted on a tripod with bearings and shaft to feed a hank making machine to prepare individual hank from individual end of the spool. The spool is self-driven with the yam tension inserted by yam process while making hank on swift of reeling machine. In total, 36 hanks are produced in the example referred to hereinabove. This machine is equipped with ya separators to avoid entanglement of yam and is driven by motor. The hank is mounted individually on individual hank holder of hank to cone winding machine to convert hank into cone of single yam. These machines have stop motions for hank as well as for cone for end breakage and works instantly. Each cone is driven individually through a friction roller driven by motor. In the present invention receiving the material (yam) directly on 6 spools in place of warper beam constitutes an aspect of invention and, wherein a cone package of single yam is converted from dyed rope of 216 ends. DESCRIPTION WITH REFERENCE TO DRAWINGS Further objects and advantages of this invention will be more apparent from the ensuing description and wherein Fig.1 shows the machine for formation of yam into separate spools on a long chain beamer; Fig,2 shows the machine for formation of the hanks; and Fig.3 shows the hank to cone winder. As described, a dyed rope of, for example, 222 ends is dyed in a manner known in the art with respect to indigo dyeing of yam for weaving of a cloth in a loom. However, in the instance of weaving of cloth in a loom, the yams of the dyed rope are individualized and then wound widthwise on a single beam, such steps being effected in a long chain beamer. Though a long chain beamer (I .CD) of Fig.1 is also employed in the present invention, the yams are no longer wound widthwise on a single beam. Instead, and if the dyed rope consists of, for example, 222 ends, the yarns are divided onto 6 separate beams or spools having 37 ends. Each spool has preferably the same number of ya s. Thus, the package of dyed rope of 222 ends is divided into 6 separate packages of 37 ends. For this purpose, the dyed rope or package 2 ends, for example, of 222 yam ends from card. Can 1 is fed to a tension stand 3 and then guided over guide pulleys 4 into an accumulator 5. The rope 2 travels into a head stock assembly 6 and finally wound onto aluminium spools 7 through separators 8. Though not shown in the drawings, such long chain beamer LCD has a vibrator to cause an individualization of the yams and a stop motion device to stop the device in the event of a breakage of ya . Each spool 7 is mounted on a tripod 9 (see Fig.2) to feed to a hank maker machine to prepare individual hank from individual yam end of a spool. The hank maker machine of Fig.2 comprises a tripod 10 for rotatably holding a shaft 11 on which spool 7 is mounted. The ends pass through a heald 12 and a stop motion device (not shown) to stop the machine in the presence of a broken end of ya . A hank 13 is wound on hank maker 14 mounted on a shaft 15. Shaft 15 has a pulley 16 adapted to be driven by a pulley 17 mounted on drive shaft 18 of a motor 19. If each spool 7 has 37 ends, 37 hanks are formed by the reeling machine of Fig.2. Each hank 20 is mounted individually on individual hank holder 21 of hank to cone winding machine 22 and as illustrated in Fig.3. The yam hank 24 is converted into a cone of single yam. For this purpose, the yam 24 from holder 21 passes through a yam guide pulley 25, a tension holding bracket 26 for holding a tensioner and gauge 27 and wound on a paper cone 28,

Claims: WE CLAIM: 1 , A process for the preparation of indigo dyed ya for use in the manufacture of knitted fabric by a knitting machine comprising in the steps of : i . forming a dyed rope of yam by the step of indigo dyeing; ii, individualizing the ya of said dyed rope; iii, forming separate packages of the ya on separate spools of fixed ends; iv. preparing individual hanks of each ya end of each spool by hank maker; v. converting said hanks into individual cones of single ya . 2, A process as claimed in claim 1 wherein each package of ya formed on said spools contain equal number of ends of yam. 3, A process as claimed in claim 1 wherein the number of hanks correspond to the number of yam on each spool. 4. A process as claimed in claim 1 wherein the dyed rope is divided and wound on separate spools in a long chain beamer. , An apparatus for the preparation of indigo dyed yam for use in the manufacture of knitted fabric comprising a long chain beamer having a plurality of individuals spools for receiving yam having equal number of ends, a hank maker for producing individual hanks and a hank to cone winder. , An apparatus as claimed in claim 5 wherein said long chain beamer has a separator so as to separate the dyed yam ends and wound on its respective spool. , An apparatus as claimed in claim 6 wherein each spool is fed to a hank maker for producing hanks.] , An apparatus as claimed in claims 6 and 7 wherein said hank maker comprises a tripod for receiving the spool mounted on a rotatable shaft, a heald for receiving the yam from said spool.

Inventors: OSWAL JANGI LAL, RASTOGI B L, OSWAL, JANGI, LAL, RASTOGI, B., L.
Applicants: MALWA COTTON SPINNING MILLS LT, OSWAL JANGI LAL, RASTOGI B L, MALWA COTTON SPINNING MILLS LTD., OSWAL, JANGI, LAL, RASTOGI, B., L.
Application year: 2001
Main classification: D06B23
IPC codes: D06B23