Patent Publication Number: US-2010107382-A1

Title: Method and device for treating a warp thread sheet

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority under 35 U.S.C. §119(a) of German Patent Application No. 10 2008 053 764.0 filed Oct. 29, 2008, the disclosure of which is expressly incorporated by reference herein in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a method for treating a warp thread sheet, in which a plurality of warp threads are drawn off from a creel and combined to form a rope that is acted on with a treatment agent. 
     The invention further relates to a device for treating a warp thread sheet, which is present in the form of a rope. The device includes a rope dispensing device and a device for acting on the rope with a treatment agent. 
     2. Discussion of Background Information 
     Textile cloth lengths are often produced using warp threads that have been previously subjected to a treatment. A typical treatment comprises dyeing the warp threads. 
     In principle a distinction is made in the handling of the threads during the treatment between two approaches: 
     In a first approach, the warp threads are combined to form a rope. A rope of this type contains in the order of magnitude of 300 to 700 warp threads. One or more ropes of this type are then acted on with the treatment agent in that, for example, they are guided through a dye bath. Thereafter, the ropes are deposited in cans. Subsequently, the rope is then wound on a warp beam in a batchwise manner and subsequently fed to a sizing machine as a warp beam. 
     In a second approach, a large plurality of warp threads (approx. 3,000 to 10,000 warp threads) are arranged next to one another in width and then acted on with the treatment agent, for example, likewise in that they are guided through a dye bath. The warp threads are drawn off from 8 to 24 warp beams and fed together to form a total number of threads. Following the dyeing, the warp threads can also be fed to a sizing machine. This method is also referred to as a “sheet dye” or “slasher dye” method. 
     Both approaches are described in BASF Technical Information “Continuous dyeing with indigo,” September 1995, page 4. 
     The treatment of a rope with the same treatment agent produces a different result from the treatment of a thread sheet of warp threads arranged next to one another. In the case of “sheet dyeing,” all of the threads are treated equally. The treatment agent can reach the threads in the same manner from all sides. 
     In the treatment of the rope, the so-called “rope dyeing,” a different thread density results in the interior of the rope. This results in a different dye extraction behavior. Accordingly, a non-uniform dyeing results, but this is often desirable in fashion. 
     The use of a rope leads to a batchwise method. The rope must be first be produced in that a large number of warp threads are drawn off from a creel, in which a correspondingly large number of bobbins are arranged. The rope formed in this manner is then wound up to form a ball in a so-called “ball warper.” In order to prevent the rope from falling off at the axial ends of the ball, the winding up is carried out in the manner of a cross-winding, i.e., with a relatively large axial displacement per revolution. At the axial ends the rope must be deflected very quickly into the other axial direction in order to maintain the necessary rope tension. In order to prevent rope windings from falling off, a relatively high thread tension is necessary. Due to the high dynamic forces that act in the area of the axial ends during the lateral displacement of the rope during the winding up and above all during the change of direction, the winding speed is limited. As a rule, a winding speed in the order of magnitude of 300 to 500 m/min is achieved. 
     In the case of “sheet dyeing,” in which the warp threads are arranged next to one another and then acted on with treatment agent, first a warp beam must be produced on which the desired number of warp threads are wound up next to one another. End plates are arranged at the axial ends of the warp beam, which end plates prevent threads from falling down here. A warp beam can be operated at much higher speeds. Operating speeds in the order of magnitude of 1,000 to 1,500 m/min are usual. A uniform thread tension treatment of all of the warp threads occurs hereby. 
     SUMMARY OF THE INVENTION 
     Embodiments of the invention produce a warp thread sheet cost-effectively. 
     According to embodiments, a method of the type mentioned at the outset includes that the warp threads, after being drawn off from the creel, are wound onto a warp beam, and are subsequently unwound from the warp beam before the impingement or treatment. Further, the warp threads are combined to form the rope between the unwinding from the warp beam and the impingement or treatment. 
     With an approach of this type, the production speed can be increased considerably, as a rule it can be even doubled. The warp threads can be wound onto the warp beam at a relatively high speed. The stresses on the warp threads are kept low hereby. In particular, extremely high thread tensions are not necessary in order to prevent ropes from falling off at the axial ends of a ball. This reduces the risk of thread breakage during the further treatment. A warp beam formed in this manner is then inserted into a take-off frame and unwound again, wherein the rope can be produced simultaneously during unwinding. Since the rope is subsequently fed to the treatment, the production of the rope is carried out “online,” as it were. The rope therefore no longer needs to be wound up between the production and the impingement with the treatment agent. Instead, the rope can be deposited in a so-called can after impingement with the treatment agent and optionally after drying, and it can be fed from the can to a further processing. Since the warp beam can be produced considerably faster than a ball or beam with a rope wound up thereon, and no additional time is needed for the formation of the rope in the take-off frame, a substantial savings in terms of time can be achieved with this approach, which has a positive effect on the production costs. 
     Preferably, the rope is produced at the same speed that the rope has during impingement in the treatment device. There is therefore no need to provide a storage device for the rope. Instead the rope can be produced at a relatively low speed, which it also has during the impingement, for example, during dyeing. A speed of this type as a rule is in the order of magnitude of 30 to 60 m/min. With a speed of this type the risk is relatively small that inadmissibly high tensions will be introduced into the warp threads. Accordingly, the risk is also low that a thread breakage will occur in the further treatment. The warp threads treated in this manner have a high quality and a better workability in subsequent processes. 
     The warp beam is preferably braked in order to produce a defined tension in the rope. Since the rope is produced at a relatively low speed, by introducing a defined tension into the rope, to be more precise, into the warp threads of the rope, the rope can be caused to assume a desired shape, in particular, a desired thickness or a desired diameter. The tension in the rope therefore has an impact on the subsequent impingement with treatment agent. The greater the tension, the closer the warp threads lie against one another and the lower, with otherwise the same conditions, the penetration of the dye pigment into the rope. The tension of the rope can thus be used within certain limits to influence the treatment result. 
     Preferably, after the rope is combined, it is only deflected and otherwise led freely up to impingement by the treatment agent. Accordingly, additional lateral tensions on the warp threads are avoided. In particular, a “trumpet unit” is not necessary to combine the rope and condense the threads. Negative effects on the warp threads are thus kept low. The warp threads are not overstretched, but can be further treated with a certain elongation reserve. 
     Further, in accordance with embodiments, a device of the type mentioned at the outset includes a rope dispensing device has a take-off frame with an outlet and at least one pick-up in which a warp beam is arranged. A rope-forming device is arranged between the pick-up and the outlet. 
     With this device, a warp beam can be used on which the warp threads can be wound at a relatively high speed. The warp beam is then unwound in the warp thread dispensing device. At the same time, the warp threads can be combined to form a thread sheet, without additional production time being necessary for this. The combination of the warp threads to form the thread sheet is carried out “online” as it were with the treatment, i.e., the impingement of the rope with the treatment agent. Since this impingement is carried out at a relatively low speed, the combination of the warp threads to form the rope can also be carried out at this low speed. This keeps the strain on the warp threads low. In particular, this prevents inadmissibly high tensions from being introduced into the rope and the warp threads from being overstretched. 
     Preferably, the rope-forming device is arranged above the warp beam. In order to form a rope from warp threads that are wound up on a warp beam, all of the threads must be brought, for example, into the area of the axial center of the warp beam, that is, also the axially outer threads. It is therefore favorable if a certain length is available between the warp beam and the rope-forming device, so that the axially outer threads can be guided into the axial center of the warp beam with low lateral tensile force. A sufficiently large distance can be provided above the warp beam between the warp beam and the rope-forming device, without it being necessary thereby to raise the warp beam unnecessarily. This facilitates handling. 
     Preferably, the pick-up has a warp beam brake. The warp beam brake is able to brake the warp beam by introducing a braking torque. When the warp beam is braked, a larger force is necessary to draw off the warp threads. This force ensures that a certain tension is produced in the warp threads and thus in the rope. The tension in the rope has a certain influence on the treatment result. As stated above, a higher tension in the rope means that the individual warp threads are packed more densely here and it is more difficult for the dye pigment to penetrate. Conversely, a looser tension in the rope means that the warp threads lie more loosely against one another and the dye pigment can penetrate better into the rope. 
     Preferably, the rope is present between the rope-forming device and the outlet in a free draw, in which it is only deflected. In particular, in the section between the rope-forming device and the outlet, no trumpet unit or other constriction is arranged through which the rope would have to be drawn, as is generally the case with a “ball warper.” Stresses on the warp threads combined in the rope are thus kept low. 
     Embodiments of the invention are directed to a method for treating a warp thread sheet. The method includes drawing off a plurality of warp threads from a creel, winding the warp threads, after being drawn off from the creel, onto a warp beam, combining the drawn off threads to form a rope, and treating the rope with a treatment agent. The warp threads are unwound from the warp beam before the treating of the rope, and the rope is formed between the unwinding from the warp beam and the treating. 
     According to features of the embodiments of the invention, the rope can be produced at a same speed that the rope has during the treating. 
     In accordance with other features of the embodiments, the method can further include braking the warp beam to produce a defined tension in the rope. 
     In embodiments, after the rope is formed, the method may further include freely guiding the rope by deflecting a rope path to the treating of the rope with the treatment agent. 
     Further, the combining of the threads can include constricting the threads from the warp beams, and guiding the constricted threads around a diversion roller with lateral disks. The combining of the threads may further include forming the rope in a constrictor arranged downstream of the diversion roller. 
     Embodiments of the invention are directed to a device for treating a warp thread sheet. The device includes a rope-dispensing device having a take-off frame with an outlet, at least one pick-up in which a warp beam is arranged, and a rope-forming device arranged between the pick-up and the outlet. The device also includes a treatment device structured and arranged to treat a rope with a treatment agent; 
     According to features of the embodiments, the rope-forming device can be arranged above the warp beam. 
     In accordance with features of the embodiments of the instant invention, the device can further include a warp brake for the pick-up. 
     According to other features of the embodiments of the invention, the device can include a deflection element arranged between the rope-forming device and the outlet to guide the rope in a free draw by deflection only. 
     In embodiments, the device can also include a warp thread sheet outlet. 
     Still further, the rope-forming device can include a diversion roller with lateral disks. The rope-forming device can further include a constrictor arranged upstream of the diversion roller that is structured and arranged to combine the threads from the warp beam. The rope-forming device can further include a constrictor arranged downstream of the diversion roller structured and arranged to form the rope. 
     Embodiments of the invention are directed to a method for treating warp threads. The method includes unwinding the warp threads from a warp beam, forming a rope from the unwound warp threads from the warp beam, and treating the rope with a treatment agent. 
     According to features of the embodiments, the forming of the rope can include combining the unwound threads, and guiding the constricted threads around a diversion roller with lateral disks. 
     In accordance with still yet other features of the embodiments of the present invention, the forming of the rope can further include combining the diverted threads to form the rope. 
     Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: 
         FIG. 1  diagrammatically illustrates a device for treating warp threads; 
         FIG. 2  illustrates an enlarged representation of a take-off frame depicted in  FIG. 1 ; 
         FIG. 3  diagrammatically illustrates a rope-forming device; and 
         FIG. 4  illustrates another view of the rope-forming device. 
     
    
    
     DETAILED DESCRIPTION OF THE PRESENT INVENTION 
     The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. 
       FIG. 1  shows diagrammatically a device  1  for treating a warp thread sheet, with a take-off frame  2  in which several warp beams  3  are arranged. In the present case twelve warp beams  3  are arranged in take-off frame  2 . However, more or fewer warp beams can also be provided, generally up to twenty-four warp beams  3 . 
     A treatment device  4 , for example a dyeing device, is arranged downstream of the take-off frame  2 . Dyeing device  4  has several baths  5 , through which warp threads  6  are guided. Dyeing device  4  is followed by a retention installation  7 . A first reaction unit  8  (e.g., oxidation frame) and a second drier device  9  are arranged downstream of retention installation  7 . A loom beam  10  is arranged after second drier device  9 . A can arrangement  11  with several cans  12 ,  13  is likewise arranged after second drier device  9 . 
     With a treatment device  1  of this type the warp threads  6  can be dyed. There are two possibilities for this. The warp threads  6  can be guided through the treatment device  1  next to one another in the width direction in a thread sheet  14  ( FIG. 2 ) and they can then be wound up on the loom beam  10 . However, the thread sheet can also be combined to form one or more ropes  15  and they can then be treated in the form of a rope  15  and then respectively deposited in the cans  12 ,  13 . 
     In the first case, the warp threads are all treated equally, so that thread sheet  14  is given a very uniform appearance. In the second case, the threads are treated in a non-uniform manner. For example, warp threads that are located in the interior of rope  15  as a rule will receive a lower dye application than the threads in the area of the circumference of rope  15 . 
     In order to be able to use both possibilities, i.e., a sheet dyeing method as well as a rope dyeing method, take-off frame  2  shown in more detail in  FIG. 2  is provided. As mentioned above, twelve or more warp beams  3  are arranged in take-off frame  2 . They are pivoted and respectively provided with a braking device  16 . A braking device  16 , which can also be referred to as a “warp beam brake,” is shown only for one warp beam  3 . However, a braking device  16  is present for each warp beam  3 . 
     The threads drawn off from warp beams  3  can be present in a thread sheet  14 , in which they are arranged next to one another in the width direction and thus form a fabric, as it were. Thread sheet  14  includes first thread sheet web  17 - 21 , in which sections  17 ,  19 ,  21  are arranged below warp beams  3 . Thread sheet  14  leaves take-off frame  2  at a first outlet  22 . 
     A second thread sheet web  23 - 25  for warp threads  28  or rope  15  formed therefrom is essentially arranged above warp beams  3 . Rope  15  leaves take-off frame  2  at a second exit  26 . As a rule, several ropes  15  are formed, one from each warp beam  3 . 
     In the exemplary illustrated embodiment, a rope-forming device  27 , which is shown in more detail in  FIGS. 3 and 4 , is arranged in or before second thread sheet webs  23 - 25 . In rope-forming device  27 , the threads drawn off from a warp beam  3  are combined to form respectively one rope  15 . Several ropes  15  are then guided parallel to one another through the rest of device  1  and deposited in cans  12 ,  13  of can arrangement  11 . 
       FIGS. 3 and 4  illustrate a thread sheet  28  being drawn off from warp beam  3  and being fed to rope-forming device  27 . Rope-forming device  27  has a diversion roller  29  with lateral disks  30 ,  31 . A spacing between lateral disks  30 ,  31  can have an impact on the subsequent width of rope  15 . A first constriction  32  is arranged upstream of diversion roller  29  in order to combine the threads of thread sheet  28 . A second constriction  33  is arranged downstream of the diversion roller  29  in order to ultimately form rope  15 . 
     Thread sheet  28  runs to rope-forming device  27  and subsequently is at most guided over diversion rollers  34 . A separation of the individual ropes is carried out by rods arranged in a fan-shaped manner. However, it is laterally combined only in rope-forming device  27 . Further devices, which could introduce lateral tensions into thread sheet  28 , can be omitted. Also in sections  24 ,  25  of second thread web, rope  15  is at most deflected via diversion rollers  35 ,  36 , but no longer laterally impinged. 
     The formation of rope  15  can be carried out at a relatively low speed. This speed is determined by the speed of subsequently arranged units  4 ,  8 , and  9 . It is, for example, in the order of magnitude of 30 to 60 m/min. Accordingly, only low forces are exerted on the threads of thread sheet  28  in the formation of rope  15 , so that there is no risk of overstressing the threads. 
     The tension in rope  15  can be regulated by braking device  16 , so that the desired density of rope  15  can be produced and thus an influence can be exerted on the dyeing result. 
     It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.