Patent Publication Number: US-7219516-B2

Title: Heat setting machine with sealing head

Description:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
     This invention relates to a machine and process for heat setting yarn, principally, but not exclusively, carpet yarn. The machine conditions twisted yarns with saturated steam to increase the crystallinity of the yarn and lock the twist or the crimp into the yarn. The machine is a continuous process machine with yarn entering one end of the machine, moving downstream through the machine and exiting the downstream end properly treated and ready for the next production step—typically winding onto yarn packages in preparation for carpet tufting. 
     In general, the heat setting machine includes a coiler or other yarn-depositing device for depositing yarn on a moving conveyor which carries the yarn into a pretreatment chamber where the yarn is heated. The yarn then passes through a set of entrance sealing rolls which maintain a pressurized environment within the system. The yarn then passes into an entrance-cooling chamber where cool, dry air is circulated through the yarn, cooling the yarn to a uniform temperature and thus allowing redevelopment of the bulk in the yarn. This cooling chamber also protects the sealing rolls from the higher temperature of the heating chamber. 
     The yarn then passes into a heating chamber where a homogeneous mixture of steam and air is circulated through the yarn. The yarn exits the heating chamber into an exit-cooling chamber where cool dry air is circulated through the yarn to reduce the yarn temperature, remove excess moisture, and protect a set of exit sealing rolls which cooperate with the entrance sealing rolls to maintain a pressurized environment within the system. The yarn then passes through the exit sealing rolls and can be further dried, separated and wound onto packages on a take-up winder which runs in synchronization with the remaining components. A yarn accumulator can be part of the system, allowing the system to continue operating during winder doffing cycles. 
     Several features are provided which differentiate the machine and method disclosed in this application from prior art machines. These features include a tunnel wherein two cooling chambers on either end of a heating chamber communicate in alignment with each other along an axis extending the length of the combined cooling and heating chambers. There is no offset from one zone to the other. This permits less expensive manufacturing and a wider conveyor belt for transporting the yarn through the system. 
     The novel system also includes an entrance and exit set of sealing rollers which maintain the pressure in the system. These sets of rollers are moved into and out of sealing position by a novel power-assist assembly such as pneumatic or hydraulic cylinders. The rollers are locked into sealing with each other by a mechanical locking device that takes the load off of the power-assist assembly and places the load onto heavy springs which provide the resilience necessary to perform the sealing function while permitting the yarn to pass between the rollers into and out of the heating chamber. 
     The invention can also include an exterior heat exchanger. 
     SUMMARY OF THE INVENTION 
     Therefore, it is an object of the invention to provide a continuous heat set tunnel for setting yarn. 
     It is another object of the invention to provide a continuous heat set line that has a conveyor that extends generally along the lateral centerline of the heat set tunnel to thereby provide for an increased conveyor width. 
     It is another object of the invention to provide a continuous heat set line with sealing head rolls that are moved into and out of sealing position by at least one piston and cylinder assembly. 
     It is another object of the invention to provide a continuous heat set line with sealing head rolls that are pressurized against each other by springs operating independently of the piston and cylinder assembly. 
     These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a continuous heat set line for setting yarn, comprising spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith. The entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof. A steam injector is provided for injecting steam at a predetermined pressure into the heat-setting chamber. Sealing means are provided for sealing the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain pressurized condition within the heat-setting chamber. A steam pretreatment chamber is positioned upstream of the entrance cooling chamber for applying a conditioning charge of steam to the yarn before it enters sealing rolls of the entrance cooling chamber. A yarn conveyor extends through the pretreatment chamber for conveying the yarn through the entrance and exit cooling chambers and the heat-setting chamber. A yarn depositing apparatus deposits the yarn in a uniform manner on the yarn conveyor upstream of the pretreatment chamber. 
     According to one preferred embodiment of the invention, the yarn depositing apparatus comprises a yarn coiler for depositing uniform, overlapping coils of yarn on the yarn conveying apparatus. 
     According to another preferred embodiment of the invention, the yarn conveying apparatus comprises an endless permeable conveyor belt extending from the coiler to downstream of the exit cooling chamber. 
     According to another preferred embodiment of the invention, a yarn packaging apparatus is provided for removing the yarn from the yarn depositing apparatus and forming the yarn into a package suitable for further downstream processing. 
     According to yet another preferred embodiment of the invention, the sealing means comprises an entrance sealing roll apparatus positioned upstream of the entrance cooling chamber and an exit sealing roll apparatus positioned downstream of the exit cooling chamber for sealing, respectively, the upstream end of the entrance cooling chamber and the downstream end of the exit cooling chamber, each of the entrance and exit sealing roll apparatuses including a pair of sealing rolls positioned adjacent each other for allowing yarn on the conveying apparatus to pass therebetween while preventing the escape of pressurized steam from within the entrance and exit cooling chambers and the intermediate steam heat-setting chamber. 
     According to yet another preferred embodiment of the invention, the yarn conveyor extends through the entrance and exit cooling chambers and the intermediate heat-setting chamber at a position functionally equidistant from a top and bottom wall thereof. 
     According to yet another preferred embodiment of the invention, the sealing means comprises a frame defining an opening through which the conveyor extends, a bottom sealing roll assembly carried by the frame, including a rotatably-mounted bottom sealing roll positioned below the conveyor, and a top sealing roll assembly carried by the frame, and including a rotatably-mounted top sealing roll mounted in spaced-apart relation to the bottom sealing roll above the conveyor whereby the conveyor extends between the bottom sealing roll and the top sealing roll for carrying the yarn past the top and bottom sealing roll assemblies and into the entrance cooling chamber. At least one piston and cylinder assembly interconnects the frame and the top sealing roll assembly for moving the top sealing roll assembly between an opened position, and a closed position wherein the top roll rests against the bottom roll. Pressurizing means exert sufficient pressure on the top roll to seal the top roll against the conveyor and the yarn carried thereon as the conveyor is supported by the bottom roll. 
     According to yet another preferred embodiment of the invention, the pressurizing means comprises springs carried by the frame for resiliently biasing the top roll against the yarn and conveyor when in its closed position. 
     According to yet another preferred embodiment of the invention, the sealing means includes lateral seals positioned to contact and seal against radially-extending end walls of the top roll and the bottom roll. 
     According to yet another preferred embodiment of the invention, a locking lever is provided for urging the top roll into contact with the conveyor. 
     According to yet another preferred embodiment of the invention, a locking pin is provided for locking the locking lever into a position with the top roll urged into contact with the conveyor. 
     According to yet another preferred embodiment of the invention, a top lamella sealingly engages the top roll along the length thereof to prevent the escape of steam and pressure past the top roll and a bottom lamella sealingly engages the bottom roll along the length thereof to prevent the escape of steam and pressure past the bottom roll. 
     According to yet another preferred embodiment of the invention, a sealing head is provided for sealing an end opening of a heat set line for setting yarn, and comprises a bottom sealing roll frame mounted adjacent the end opening and carrying a rotatably-mounted bottom sealing roll, and a top sealing roll frame carrying a rotatably-mounted top sealing roll, the top sealing roll frame mounted on the bottom sealing roll frame for movement between an open, non-sealing position and a closed sealing position with the top roll engaging a yarn conveyor extending between the top and bottom rolls and into the heat set line for conveying the yarn into the heat set line. At least one piston and cylinder assembly interconnects the top and bottom sealing roll frames for power-assisted movement of the top sealing roll frame between the open and closed positions. 
     According to yet another preferred embodiment of the invention, pressurizing springs are carried by the top sealing roll frame for resiliently biasing the top roll against the conveyor when in its closed, sealing position. 
     According to yet another preferred embodiment of the invention, lateral seals are positioned to contact and seal against radially-extending end walls of the top roll and the bottom roll. 
     According to yet another preferred embodiment of the invention, a locking lever is provided for urging the top roll into contact with the conveyor. 
     According to yet another preferred embodiment of the invention, a locking pin is provided for locking the locking lever into a position with the top roll urged into contact with the conveyor. 
     According to yet another preferred embodiment of the invention, a top lamella sealingly engages the top roll along the length thereof to prevent escape of steam and pressure from the heat set line past the top roll and a bottom lamella sealingly engages the bottom roll along the length thereof to prevent the escape of steam and pressure past the bottom roll. 
     According to yet another preferred embodiment of the invention, the at least one piston and cylinder assembly comprises a pair of piston and cylinder assemblies interconnecting the top sealing roll frame and the bottom sealing roll frame on opposite lateral sides thereof for balanced movement of the top sealing roll frame relative to the bottom sealing roll frame. 
     According to yet another preferred embodiment of the invention, the pair of piston and cylinder assemblies are hydraulically powered. 
     According to yet another preferred embodiment of the invention, the end opening comprises an entrance to the heat set line and the sealing head is positioned upstream of the entrance for sealing the entrance against loss of pressure and steam. 
     According to yet another preferred embodiment of the invention, the end opening comprises an exit from the heat set line and the sealing head is positioned downstream of the exit for sealing the exit against loss of pressure and steam. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which: 
         FIG. 1  is a vertical cross-section of a prior art heating tunnel; 
         FIG. 2A  is a side elevation of a heat set tunnel according to the present invention; 
         FIG. 2B  is a vertical cross-sectional view of a heat seat tunnel according to the invention; 
         FIG. 3  is a vertical cross section of a heating tunnel according to one embodiment of the invention; 
         FIG. 4  is a vertical cross section of a heating tunnel according to another embodiment of the invention including an external heat exchanger; 
         FIG. 5  is a vertical cross section of a heating tunnel according to another embodiment of the invention including an external sump; 
         FIG. 6  is a vertical cross section of a heating tunnel according to another embodiment of the invention including an external sump and an exterior heat exchanger; 
         FIG. 7  is a vertical cross-section of the exit and entrance cooling sections; 
         FIGS. 8   a – 8   d  shows four views of the of the entrance and exit sealing head; 
         FIG. 9   a  is a perspective view of the sealing head in the closed, sealing position; 
         FIG. 9   b  is a perspective view from the rear of the sealing head in the closed, sealing position; 
         FIG. 9   c  is perspective view from the rear of the sealing head in the closed, sealing position, with parts removed for clarity; 
         FIG. 9   d  is a top plan view of the sealing head; 
         FIG. 9   e  is a side elevation of the sealing head in the closed, sealing position; and 
         FIG. 9   f  is a front elevation of the sealing head in the closed, sealing position. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE 
     Referring now specifically to the drawings, a cross-section of a portion of a tubular heat set tunnel according to a prior art design is illustrated in  FIG. 1  at reference numeral  1 . The section represents the configuration of a central portion of the tunnel wherein the belt  2  is 260 mm wide and resides 50 mm above the centerline of the tunnel section  1 . The belt  2  is positioned 100 mm above the waterline. Positioning the belt above the centerline of the tunnel section  1  limits the width of the belt to a width less than would be possible at the centerline diameter of the tunnel. This design, described in U.S. Pat. No. 5,092,139, discloses positioning the central heating chamber with a longitudinally-extending axis which is disposed lower than the cooling chambers on either end, having the effect of moving the belt in the heat setting tunnel closer to the longitudinally-extending axis of the heat setting tunnel, but still above the centerline by approximately ⅙ to 1/10 the diameter of the chamber. The &#39;139 patent teaches that this arrangement is essential. 
     The invention according to the present invention is disclosed in  FIGS. 2–18 , inclusive. As is shown in  FIGS. 2A and 2B , the heat set tunnel  10  according to the invention extends longitudinally along a supporting floor surface and includes on one end an entrance sealing roll assembly  20  and on the other end an exit sealing roll assembly  30 . Downstream of the entrance sealing roll assembly  20  is an entrance cooling section  40  connected by a cool/heat transition  41  to a steaming chamber  50  comprised of tubular elongate entry, intermediate and exit heat set tunnel segments  51 ,  52  and  53 , respectively. A heat/cool transition  54  interconnects the exit heat set tunnel segment  53  with an exit cooling section  60 . 
     The entrance cooling section  40  includes an exterior heat exchanger  42  which takes heated yarn from a pre-treatment steaming chamber, not shown, and circulates cool, dry air through the yarn by means of a fan  43 , cooling the yarn to a uniform temperature and allowing bulk to redevelop in the yarn after passing under the rolls of the sealing roll assembly  20 . See  FIG. 7 . The yarn then passes through the cool/heat transition  41  and into the entry heat set tunnel segment  51  where the yarn is heated again by live steam and heated air to a temperature sufficient to set the bulk in the yarn. Air and steam is circulated through the tunnel segments  51 ,  52  and  53  by an exterior recirculation conduit  55  and a fan  56 . 
     The treated yarn passes through the heat/cool transition  54  into the exit cooling section which cools the yarn as it protects the rolls of the exit sealing roll assembly  30 . The yarn is then conveyed to a winder where the yarn is packaged on suitable yarn packages and is ready for further processing. 
     The preferred embodiment of the heat set tunnel segment  51  is shown in  FIG. 3 , and is exemplary of tunnel segments  52  and  53 . A sheet metal drip shield  56  extends along the upper extent of the tunnel segment  51  and encloses a conveyor belt  57  which extends the length of the heat set tunnel  10 . In the lower portion of the tunnel segment  51  are two longitudinally-extending closed steam coils  58 A and  58 B which are used to bring water in the lower portion of the tunnel  51  up to temperature. At this point these coils  58 A and  58 B are shut off and live steam is introduced into the tunnel segment  51  through a perforated sparger  59 . Note that the conveyor belt  57  extends very nearly along the diameter of the tunnel segment  51 . 
     Another embodiment of a tunnel segment is shown in  FIG. 4  at reference numeral  80 , and includes an elongate tubular enclosure  81  within which is located a conveyor  82  within a sheet metal drip shield  83 . Water in the bottom of tunnel segment  80  is heated to temperature by a circulating external heat exchanger  84 . A sparger  85  then supplies live steam to the tubular enclosure  81 . 
     Another embodiment of a tunnel segment is shown in  FIG. 5  at reference numeral  90 , and includes an elongate tubular enclosure  91  within which is located a conveyor  92  within a sheet metal drip shield  93 . Water in the bottom of tunnel segment  80  is heated to temperature in a sump  95  in which is contained two closed steam coils  96 A,  96 B and a sparger  97 . After the water has been brought up to proper temperature, the sparger  97  then supplies live steam to the tubular enclosure  91 . 
     Another embodiment of a tunnel segment is shown in  FIG. 6  at reference numeral  100 , and includes an elongate tubular enclosure  101  within which is located a conveyor  102  within a sheet metal drip shield  103 . Water in the bottom of tunnel segment  80  is heated to temperature in a sump  105  by means of an external heat exchanger  107 . A sparger  97  then supplies live steam to the tubular enclosure  91  to properly set the bulk in the yarn. 
     The entrance roll sealing assembly  20  is shown in  FIGS. 8   a  through  9   f . The exit roll sealing assembly  30  has the same construction. The entrance roll sealing assembly  20  includes an entrance opening  120  through which the conveyor  57  passes into the entrance cooling section  40 . A bottom sealing roll frame  121  mounts bottom drive gears  122 A,  122 B, the shaft of which carries a bottom sealing roll  123  and hydraulic cylinder assemblies  124 A,  124 B. Piston rods  125 A,  125 B of the respective hydraulic cylinder assemblies  124 A,  124 B are pivotally connected to the top sealing roll frame  126 . The top sealing roll frame  126  is pivotally mounted to the bottom sealing roll frame  121  by a pivot shaft  127 . The distance and angle between the pivot of the piston rods  125 A,  125 B and the pivot shaft  127  provides a lever arm which permits the top sealing roll frame  126  to be moved between a closed position,  FIGS. 8   a ,  8   b , and an open position,  FIGS. 8   c ,  8   d , by the actuation of the hydraulic cylinder assemblies  124 A,  124 B. While it is presently believed that hydraulic cylinders will best perform the function described above, pneumatic cylinders, worm gears, ball screw gears or other power assist mechanisms are also possible. 
     The top sealing roll frame  126  carries a top sealing roll  130 ,  FIGS. 8   b ,  8   c  which is rotated by driven gears  132 A,  132 B meshed with and driven by drive gears  122 A,  122 B. The rolls  123  and  130  thus rotate against each other and provide a seal along their length, preventing the escape of pressure in the heating tunnel segments  51 ,  52 ,  53 . 
     The sealing pressure against the rolls  123  and  130  necessary to prevent the escape of pressure is provided by opposed sets of heavy steel springs  135 ,  136  mounted between the top sealing roll frame  126  and a top pressure plate  138 . Adjustment screws  139  and  140  permit adjustment of the springs to the correct pressure to seal the rolls  123  and  130  against each other while not creating so much pressure that the roll bearings are damaged. 
     The hydraulic cylinders  124 A,  124 B serve only to raise and lower the top sealing roll frame  126  relative to the bottom sealing roll frame  121 . When, for example, the top sealing roll frame  126  has been lowered onto the bottom sealing roll frame  121  by the hydraulic cylinders  124 A,  124 B, pressure is applied to the rolls  123 ,  130  by means of a locking lever  150  which is manually urged into a locking link assembly  151 . See  FIG. 9   b . A locking cylinder  153  locks the locking lever  150  in its locked position, and a link pin  155  locks the locking link assembly  151  in its down, sealing and locked position. 
     As is best shown in  FIG. 8   b , top and bottom lamellas  160 ,  161  are urged against the front side of the top and bottom sealing rolls  130 ,  123 , respectively, and seal against pressure escaping around the top of the top roll  130  and the bottom roll  123 . Similarly, side cylinders  163 ,  164  urge side pressure plates  166 ,  167  against the opposed ends of the sealing rolls  123 ,  130  to prevent pressure leaks past the ends of the rolls  123 ,  130 . See  FIG. 9   d.    
     Yarn passing through the entrance sealing roll assembly  20  on the conveyor belt  57  is compressed as it passes between the top and bottom sealing rolls  130 ,  123  to the extent that pressure cannot escape past the compressed yarn.  FIG. 9   e . Thus, the pressurized interior of the heat set tunnel  10  is effectively sealed at the entrance end from the surrounding atmosphere. 
     The entire entrance sealing roll assembly  20  can be covered by a protective shroud  170 , as shown in  FIG. 13 .  FIG. 9   a.    
     As noted above, an identical exit roll sealing assembly  30  positioned in the exit end of the heat set tunnel  10  performs the identical function at the exit end, creating a closed environment for the heat set operation. 
     A heat setting machine with a sealing head is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.