Abstract:
A method and apparatus are disclosed for fabrication of textiles. The method includes the step of passing a yarn or product along a path through a device. The method also includes applying a rotation force to the yarn or product with at least one jet of liquid directed by the device.

Description:
RELATED APPLICATIONS 
     This application is a continuation in part of U.S. patent application Ser. No. 09/356,687, filed Jul. 20, 1999 now U.S. Pat. No. 6,139,588, which is a continuation of U.S. patent application Ser. No. 08/737,653, filed Nov. 22, 1996, now U.S. Pat. No. 5,931,972, which claims priority under 35 U.S.C. §119 and 37 C.F.R. §1.55 which is a 371 of International Application No. PCT/GB95/01170 filed May 23, 1995; Great Britain Patent Application Serial No. 9410379.3, filed May 24, 1994; Great Britain Patent Application Serial No. 9915924.6, filed Jul. 8, 1999; Great Britain Patent Application Serial No. 9915923.8, filed Jul. 8, 1999; and Great Britain Patent Application Serial No. 9915922.0, filed Jul. 8, 1999. 
     This application also is related to a co-pending U.S. Patent Application entitled “Apparatus and Method for Texturing Yarn,” Ser. No. 09/513,802, filed on Feb. 25, 2000, having the same common assignee, and incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to an apparatus and method for fabrication of textiles or the like, and in particular to the use of liquid jets to false twist textile filament yarns and twist textile staple products such as yarn, sliver or roving. 
     BACKGROUND OF THE INVENTION 
     It is known to apply a twist to a textile staple product to give the product satisfactory coherence by passing the product through a twisting jet in which a jet or jets of air are directed onto the traveling product offset from its axis to impart a twisting torque to the product. The diameter of a textile product is relatively small, for example jet manufacture are extremely tight if satisfactory processing is to be achieved and consistency of performance from jet to jet. Typically, a textile machine for performing such a process can have over 200 processing stations, i.e., over 200 yarns are processed simultaneously in parallel threadlines. This means that the machines are very large, which leads to problems of ergonomics. Furthermore, the provision of tight tolerance texturing jets and high pressure air to such jets is expensive and such a machine is very noisy, particularly when one or more doors of the jet boxes are open for threading purposes. 
     It has also been proposed to use a texturing jet to apply a false twist to a textile filament yarn. This proposed method consists of passing the yarn through a texturing jet wherein, like the twisting jet described above, a jet or jets of air are directed onto the traveling yarn offset from its axis to impart a twisting torque to the yarn. The twist levels achievable by this method are very low by comparison with those achieved by the use of friction discs, belts and the like, hence the limited use commercially. The tolerances on this type of air jet manufacture are especially tight since the diameter of a textile yarn, for example 0.2 mm for 150 Denier, is even smaller than when using an air jet to apply a twist to a textile staple product. In addition, since from a production costs point of view it is desirable to increase the yarn processing speed as much as possible, a limit on such speed is the surge speed, the speed at which satisfactory processing breaks down due to the long uncontrolled lengths of yarn in the machine. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method of applying twist to a textile product comprising passing the product along a path through a device while applying a rotational force to the product with at least one jet of liquid directed by the device. 
     The method can also comprise applying a forwarding force to the product. The method can comprise applying at least one axially offset jet of liquid to the surface of the product. The method can comprise applying the at least one jet of liquid with components of velocity both along and laterally of the path through the jet device. The method can comprise applying a plurality of jets of liquid disposed about the path through the jet device, which jets can be symmetrically disposed. Preferably, three such jets of liquid are provided. Preferably the liquid is water and can be cold water. The method can also comprise passing the product successively through a plurality of liquid jet devices. Consecutive jet devices can apply rotational forces to the product in the same or in opposite directions. 
     The invention also provides a process, in which a twist is applied to the product by the above method, comprising controlling the product by a feedback arrangement. In this case, a property of the product can be measured and the measurement used to control the product processing. The measurement can be used to control the liquid jet device or the product speed. 
     The process can comprise cooling the product. The product can be cooled by the liquid jet device. 
     The invention can also comprise an apparatus for applying twist to a textile product comprising a liquid jet device adapted to apply a rotational force to a product traveling along a path through the jet device. 
     The liquid jet device can be adapted to apply a forwarding force to the traveling product. The jet device can apply at least one axially offset jet of liquid to the surface of the product. The at least one jet of liquid can be directed to have velocity components both along and laterally of the path through the jet device. A plurality of jets can be disposed about the path. through the jet device, preferably symmetrically. Three such jets can be provided. The liquid jet device can comprise a housing having an axial bore terminating in a product constricting outlet, the axis of the bore defining a path therethrough, with at least one liquid flow channel aimed towards the outlet and offset from the axis. The liquid jet device can comprise a casing having at least one seal against liquid escape along the path. The seal can be a labyrinth seal and can be pressurized. The seal can be gas pressurized, and can be pressurized by compressed air. Preferably the liquid jet device comprises a water jet device. A plurality of liquid jet devices can be disposed successively along the path, and the plurality of jet devices can be provided in a common casing. Three such jet devices can be so provided. Consecutive liquid jet devices can be adapted to apply rotational forces to the product in the same or in opposite directions. 
     The apparatus can comprise a feedback arrangement operable to control the product processing. The feedback arrangement can comprise a measuring instrument operable to measure a property of the product and produce a signal proportional to the measurement, and control means operable in response to the signal to control the product processing. The control means can be operable to control the rate or the pressure of the flow of liquid to the liquid jet device or the product speed. 
     The apparatus can comprise cooling apparatus, which can comprise the liquid jet device. The apparatus can also comprise winding apparatus disposed downstream of the liquid jet device. 
     The present invention also provides a method of applying a false twist to a textile filament yarn comprising passing the yarn along a yarn path while applying a rotational force to the yarn by a liquid jet device. 
     The invention also provides a process for applying twist to a filament yarn, in which the false twist is applied to the yarn by the above method and the yarn is cooled. The yarn can be cooled by the liquid jet device. The yarn can be heated prior to being cooled and twisted, and can then be wound up. The yarn can be passed through a twist trap, a heating zone, a cooling zone and the liquid jet device, being twisted by the latter so that the twist runs back to the twist trap, and then wound up. The yarn can be heated as far upstream as the twist trap. The yarn can be heated prior to passing through the twist trap and not further heated between the twist trap and the liquid jet device. The yarn can be drawn prior to being cooled and twisted. 
     The yarn can be cooled by immersion in a cooling liquid, in which case the cooling liquid can be moved in contraflow to the yarn passing through the cooling zone. The cooling zone and the liquid jet device can be contiguous. The cooling liquid can be the liquid of the jet device. The process can comprise heating the yarn by vapor, which can be superheated steam. 
     The yarn can be post-treated prior to it being wound up. In this case, the yarn can be passed with controlled overfeed through heating apparatus. The heating apparatus can comprise vapor heating, which can be superheated steam. 
     The invention can also comprise an apparatus for applying twist to a textile filament yarn comprising a liquid jet device adapted to apply a rotational force to a yarn traveling along a yarn path through the jet device. 
     The apparatus can also comprise a yarn heating apparatus, which can be upstream of the cooling apparatus. The apparatus can comprise winding apparatus disposed downstream of the liquid jet device. The apparatus can also comprise drawing means, which can be disposed upstream of the cooling apparatus. The heating apparatus, cooling apparatus and liquid jet device can be mounted in a common housing. 
     The yarn cooling apparatus can be a fluid cooling apparatus in which the yarn passes through a fluid to be cooled by heat transfer thereto. The yarn cooling apparatus can comprise a cooling chamber with a fluid inlet and a fluid outlet for cooling fluid to be passed therethrough, and a yarn inlet and yarn outlet. The cooling fluid can be passed contraflow relative to the yarn. The cooling chamber can comprise seals against escape of cooling fluid at the yarn inlet and the yarn outlet. The seals can be labyrinth seals and can be pressurized. The seals can be gas pressurized, and can be pressurized by compressed air. The cooling fluid can be a liquid and can be water. The flow of liquid through the cooling chamber can be arranged to be turbulent. The liquid jet device and the cooling apparatus can have a common liquid. 
     The heating apparatus can comprise a vapor heating apparatus. The vapor can be superheated steam. The heating apparatus can comprise a housing having seals against escape of steam at a yarn inlet and at a yarn outlet thereof The seals can be labyrinth seals and can be pressurized. The seals can be gas pressurized, and can be pressurized by compressed air or by superheated steam. The heating apparatus, the cooling apparatus and the liquid jet device can be disposed in a common housing. 
     The apparatus can also comprise treatment means operable to post treat the yarn. In this case, the apparatus can comprise feed means operable to pass the yarn with controlled overfeed through a further heating apparatus. The further heating apparatus can be a vapor heating apparatus. The heating apparatus and the further heating apparatus can use the same vapor in sequence. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will now be described with reference to the accompanying drawings in which: 
     FIG. 1 is a section on the line  1 — 1  of FIG. 2 of a liquid jet device; 
     FIG. 2 is a section on the line  2 — 2  of FIG. 1 of the liquid jet device; 
     FIG. 3 is a section of a multi-head liquid jet device; 
     FIG. 4 is a threadline diagram of a false twist texturing machine incorporating the liquid jet device of FIGS. 1 and 2; 
     FIGS. 5 and 6 are alternative embodiments of the twisting machine; and, 
     FIG. 7 is a threadline diagram of a staple twisting machine incorporating the liquid jet device of FIGS.  1  and  2 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIGS. 1 and 2, there is shown a liquid jet device  10  in the form of a cylindrical housing  11  having an insert  12  in which there is a stepped bore  13  defining an axial path for a textile filament yarn or textile staple product  14  to pass through the jet  10 . A supply  15  supplies water or other suitable liquid in the direction of arrow A to the annular space  16  between the housing  11  and the insert  12 . The downstream end of the insert  12  and the annular space  16  are of co-operating conical form. In the conical end  17  of the insert  12  are grooves  18  which are offset from the axis of the smaller diameter part  19  of the bore  13 , three such grooves  18  being shown in this case symmetrically disposed around the yarn or product  14 . The grooves  18 , being offset from the axis of the bore  19 , provide that the impinging jets of water subject the textile filament yarn or textile staple product to a torque that false twists a textile filament yarn or twist a textile staple product, respectively. The grooves  18 , which can be straight as shown or can be formed spirally in the conical end  17 , are directed at an angle to the direction of running of the yarn or product  14  so that the water jets have components of velocity along the path of the yarn or product  14  as well as laterally thereof This applies a forwarding force to the yarn or product  14  as well as the twisting torque. The flatter the cone  17 , i.e., the greater the cone angle θ, the more is the twisting torque and the less is the forwarding force and vice versa. A drain tube or block  20  is attached to the housing  11  and has a bore  21  which is aligned with the bore  19 , both of which bores  19 ,  21  have substantially the same diameter as that of the yarn or product  14  so as to prevent the egress of water therealong. The water preferentially exits from the drain tube or block  20  in the direction of arrow B through an outlet  22 . Three such water outlets  22  can be provided in the drain tube or block  20 , each substantially in alignment with one of the grooves  18 . 
     Referring now to FIG. 3, there is shown a multi-head twist unit  30 . Within a housing  31  are three axially aligned liquid jet devices  32  similar to the type shown in FIGS. 1 and 2 and mounted in a casing  33 . Parts of jet devices  32  corresponding with those of jet device  10  are identified by the same reference numerals. In the case of jet devices  32  however, the bores  19  are not stepped and extend the full length of the inserts  12 . In addition, drain tubes or blocks  20  are omitted and the water, having impinged on the yarn or product  14  running successively through bores  19  of the three jet devices  32 , exits from the casing  33  through drain holes  34  into the annular space  35  between the casing  33  and the housing  31 . Water outlets  36  are provided in the housing  31 , and in the case that the twist unit  30  is a “stand-alone” unit, labyrinth seals  37  are provided at each end of the housing  31 . Compressed air is provided in the direction of arrows C to pressurize the seals  37  to prevent water egress from the housing  31  along the path of the yarn or product  14 . The use of the multi-head apparatus  30  provides that each successive jet device  32  augments the twist in the yarn or product  14  inserted by the previous jet device  32 . Alternatively, in twisting textile staple products such as yarn sliver or roving, the consecutive jet devices  32  can be arranged to impart opposite twist to the product  14 , i.e., alternatively S and Z twist so that the resulting product  14  has alternative lengths of S and Z twist therein. The cone angles of the cones  17  of the three jet devices  32  can be progressively smaller whereby the first jet device  32  imparts more twisting torque and less forwarding force and the later jet devices  32  impart successively less twisting torque and greater forwarding force to the yarn or product  14 . 
     An embodiment of a false twist texturing machine arrangement  40  is shown in FIG.  4 . Typically, the yarn  41  is partially drawn and is supplied on supply packages  42  mounted in a creel  43 . The yarns  41  are withdrawn from the packages  42  by a first feed roller pair  44  and fed to a primary heater  45 , and then around a guide roller  46  to a cooling device  47 . From the cooling device  47  the yarn  41  passes through a false twist device  48  and a second feed roller pair  49 . The false twist device  48  imparts a false twist to the yarn  41  which twist runs back to the first feed rollers  44 , these acting as a twist stop device. The heating device  45  heats the twisted yarn  41  which retains the twist memory as it is cooled in the cooling device  47 . The thus textured stretch yarn  50  can be passed directly to a take-up arrangement  51  in which it is wound onto a bobbin  52  driven by surface contact with a driving bowl  53 . Alternatively, the textured yarn  50  can be passed through a setting or second heater  54  to become set yarn  55  before passing to the take-up arrangement  51 . In this case, a third feed roller pair  56 , which forwards the set yarn  55  to the take-up arrangement  51 , is driven at a lower peripheral speed than that of the second feed rollers  49  so that the heating of the textured yarn  50  in the second heater  54  is at a controlled overfeed. 
     In the case of this invention, the false twisting device  48  is constructed and operates as the device  10  of FIGS. 1 and 2 or device  30  of FIG. 3, with water being introduced into the false twist device  48  in the direction of arrow A as described above. The cooling device  47  is a cylinder through which the heated yarn  41  passes and into which cooling water is introduced in the direction of arrow D and from which the water exits in the direction of arrow E. With this arrangement, the cooling water passes along the cooling device  47  in turbulent contraflow to the running yarn  41 , both of which factors enhance the transfer of heat from the yarn  41  to the cooling water. At the opposed ends of the cooling device  47 , the yarn inlet and yarn outlet are provided with seals  57  which can be pressurized against escape of water therethrough as shown and described in respect of seals  15 ,  37  of the false twist devices  10  and  30 . 
     Conventionally, the heater  45  is a relatively long plate at a temperature close to the melting temperature of the yarn  41  and in contact with which the yarn  41  runs. Alternatively, to reduce the overall size of the machine  40 , the primary heater can be a short non-contact heater at a temperature considerably higher than the melting temperature of the yarn  41 . As an alternative, the roller  46  can be heated in order to heat the yarn  41  as it passes therearound. However, in this case, the primary heater  45  is a vapor heating chamber through which the yarn  41  runs, the preferred vapor being pressure steam. A further roller  58  is disposed to combine with the guide roller  46  to form the twist stop which inhibits twist from running upstream of the rollers  46 ,  58 . The untwisted yarn  41  is more receptive to heat transfer than twisted yarn, so that the heater  45  can be smaller than even the short high temperature heaters referred to above. The peripheral speed of the rollers  46 ,  58  is greater than that of the first feed rollers  44  so that the heated yarn  41  is drawn between them. The yarn  41  is heated sufficiently by the steam in heater  45  prior to passing through the twist stop rollers  46 ,  58  that no further heating is required between the twist stop rollers  46 ,  58  and the false twist device  48 . The heat in the yarn  41  is sufficient as it passes into the cooling device  47  for the yarn  41  to retain its twist memory. Due to the turbulent contraflow of cooling liquid in the cooling device  47 , this cooling device  47  is shorter than conventional free-air or plate contact cooling arrangements. 
     Referring now to FIG. 5, there is shown a false twist texturing machine  60  having many of the components as described in respect of machine  40  of FIG.  4 . Corresponding components are identified by the same reference numerals. In this machine arrangement, the heating, cooling and false twisting device are shown to be contiguous, and the heating for the drawing step between the first feed rollers  44  and the rollers  46 ,  58  is provided by a heated draw pin  59 . The primary heating, cooling and false twisting device  61  comprises a housing  62  having labyrinth seals  63  at the entrance and exit for the yarn  41 . The labyrinth seals  63  are pressurized, to prevent water egress from the interior of the housing  62 , by compressed air supplied in the direction of arrows C. Within the housing  62  is, in sequence, a primary heating apparatus  64  and a cooling and twisting apparatus  65 . The heating apparatus  64  has a steam inlet  66  and a steam outlet  67 , the yarn  41  being heated by the steam as it passes along the bore  68  of the heating apparatus  64 . The cooling and false twisting apparatus  65  shown is a single head apparatus  10  as shown in FIGS. 1 and 2, but preferably a multi-head apparatus  30  as shown in FIG. 3 is provided in order to increase the twist level imparted to the yarn  41 . As the heated yarn  41  passes into the cooling and false twisting apparatus  65 , it is first cooled, in a cooling zone  38  (see FIG.  3 ), due to the effect of the cold water passing through the apparatus  65 . In this cooling zone  38 , the cooling water passes in turbulent contraflow to the running yarn  41 , both of which factors enhance the transfer of heat from the yarn  41  to the cooling water. The jets of water impinging laterally on the yarn  41  impart a false twist to the yarn  41 . This twist runs back through the cooling zone  38  and heating apparatus  64  to the first feed rollers  44 , these acting as a twist stop device. The heating device  64  heats the twisted yarn  41  which retains the twist memory as it is cooled in the cooling zone  38 . 
     Another significant difference between the machines  40  and  60  is that in the case of machine  60  there is shown a measuring instrument  70  which measures a property of the stretch yarn  50 . Such parameter can be elasticity or crimp modulus. The measuring instrument  70  sends a signal proportional to the value of the measured parameter to a controller  71  which compares that value with a predetermined desired value. If there is a discrepancy between the two values, the controller  71  is operable to control the rate and pressure of the water flow to the false twist apparatus  65 , the speed of the feed rollers  44 ,  49  and/or the temperatures of the heating apparatus  64 . 
     In FIG. 6 there is shown a machine  72  which is identical with machine  60  of FIG. 5 except that a second post treatment or setting heater  73  is provided. The textured yarn  50  runs through the secondary heater  73  under controlled overfeed conditions between second feed rollers  49  and third feed rollers  56  to receive its setting heating. The set yarn  74  then passes to the take-up arrangement  51 . The steam issuing from the primary heater  64  is passed to the secondary heater  73 , being further heated or cooled as required under the control of the controller  71  in response to the signal from the measuring instrument  70  which measures a parameter of the set yarn  74 . 
     Although the embodiments of false twisting apparatus shown are fixed units, the individual jets of water can be individually mounted in the housing so that each is adjustable in respect of its spacing from the axis of the yarn to increase or decrease the twisting torque provided by a specific size of jet of water. 
     A staple twisting and drawing machine arrangement  140  embodying the above described twisting device  10  is shown in FIG. 7 The supply of staple product  141  is provided in this case on a supply package  142 , but the supply could be directly from a carding machine or other processing machine (not shown). The product  141  is withdrawn from the package  142  by a first feed roller pair  143 . The product  141  is then forwarded to a twisting device  147 . From the twisting device  147  the twisted staple product  148  passes via a second feed roller pair  149  to a take up arrangement  150  in which it is wound onto a bobbin  151  driven by surface contact with a driving bowl  152 . The twist device  147  imparts a false twist to the product  141  which twist traps the staple fibers into the product  141  to give coherence to the twisted product  148 . 
     In the case of this invention, the twisting device  147  is constructed and operates as the device  10  of FIGS. 1 and 2 or alternatively device  30  of FIG. 3, with water being introduced into the twisting device  147  in the direction of arrow A as described above. In this case, the twisting apparatus  147  shown is a single head apparatus  10  as shown in FIGS. 1 and 2, but preferably a multi-head apparatus  30  as shown in FIG. 3 is provided in order to increase the twist level imparted to the product  141  or provide alternate lengths of S and Z twisted product  141  depending on whether consecutive jet devices  32  (FIG. 3) are arranged to twist the product  141  in the same direction or in opposite directions. If the product  141  is in a heated condition as it passes into the twisting device  147  it can be cooled, in a cooling zone  38  (see FIG.  3 ), due to the effect of the cold water passing through the twisting device  147 . In this cooling zone  38 , the cooling water passes in turbulent flow around the running yarn  141 , which enhances the transfer of heat from the yarn  141  to the cooling water. The water, after impinging o the product  141 , leaves the casing  153  in the direction of arrow B, being prevented from escaping from the casing  153  along the path of the product  141  by labyrinth seals  154 . 
     A measuring instrument  155  is provided to measure a property of the twisted staple product  148 . Such parameter can be bulk or hairiness. The measuring instrument  155  sends a signal proportional to the value of the measured parameter to a control  56  which compares that value with a predetermined desired value. If there is a discrepancy between the two values, the controller  156  is operable to control the rate and/or pressure of the water flow to the twisting device  147 , and/or the speed of the feed rollers  143  and  149 . 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiment illustrated.