CA1097094A - Textile transfer padding process and apparatus - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A method of applying small amounts of liquid to a textile. Liquid is applied to a meter roll by rotat-ing it while partially immersed in a pan of liquid to lift the liquid. The liquid is transferred to a transfer roll through a small space, and the transfer roll applies a thin film of the liquid to a pad roll.
Two soft rubber pad rolls are used, one driven and the other freely rotatable. The two pad rolls are pressed against opposite sides of the fabric so that the freely rotatable roll is rotated by the driven roll. The pad rolls work the fabric to distribute the liquid through it.

Description

109 709~ .

DISCL~SURE
The present invention is concerned with a pro-cess for the application of liquid treating agents to textile fabrics.
BACKGROUND O~ THE INVEN~ION
A commonly used procedure for applying liquid treating agents to fabrics is padding, which involves immersion of the fa~ric in the liquid and then s~ueezing the fabric to impregnate the fabric and expel excess liquid. In spite of the squeezin~ action of the pad rolls, large quantities of liquid are taken up in the fabric. Subsequently, the fabric must be dried and therefore lar~e amounts of heat must be applied to -cause al~ o~ this water to evaporate. As a result, the ener~y requirements o~ textile finishing operat~ons are very substantial. Another procedure invol~es spraying the liquid onto the surface of the fabric. Spraying permits better control of the amount of liquid applied.
However, it also reduces the penetration o~ the liquid into the fabric which, in many, if not most, ca~es limits the usefulness o~ the process. Attempts ha~e been made t~ use suction to draw the liquid into the abric, but the penetration achieved ~as much less than observed in padding~

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~09~7~94 SUMMARY OF THE INVENTION
The present invention is concerned with a pro-cess for applying liquid to fabrics which is capable - of applying small quantities to the surface of the fabrics and then working those small amounts of liquid into the fabric. As a result, the deep penetration, characteristic of a padding process is achieved at much lower liquid application rates. Therefore, the energy re~uired to remove water is reduced, and even eliminated entirely in some cases.
In accordance with the present invention, the fabric is squeeæed between a pair of large diameter soft rubber rolls which are rotated so that their surfaces move in the same direction as the fabric. A
thin film of liquid is applied to the surface of one or both of the rubber rolls which is transferred to the surface of the fabric as the fabric is propelled between the rolls. The action of the rolls then moves the liquid into the interior of the fabric. By con-trolling the pressure o the rolls and the amount ofliquid applied, it is possible to control the penetra-tion of liquid into the fabric to achieve a variety of interesting effects.
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lV~7094 BRIEF DESCRIPTION OF DRAWING
-The process will be understood more readily from the detailed description of preferred embodiments which follows, reference being made to the drawing in which:
FIGURE 1 is a schematic illustration of a transfer padding apparatus useful in carrying out the process of the invention;
FIGURE 2 is a schematic illustration of the apparatus of FIGURE 1, depicting an alternate mode of operation which is used when especially small quanti-ties of liquid are to be applied;
FIGURE 3 is a schematic view on enlarged scale of a portion of FIGURE 1, showing the action of the pad rolls on the fabric.

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`5--DETAILED DESCRIPTION OF PREFERRED EMBODIME~TS
As illustrated in FIGURE 1, the process consists of passing a fabric 1 between a pair of pad rolls 2 and 3 which are rotated so that their surfaces move in the same direction as the fabric. The pad rolls typically comprise a soft rubber cover 4 enclosing a metal shaft 5. The rolls are pressed against the fabric with sufficient pressure to flatten their surfaces along a contact zone 6 between the rolls, extending along the direction in which the fabric is moving. A bowed roll 7 is provided just below the nip between the pad rolls which feathers the fabric in the contact zone 6. Below the pad rolls 2 and 3 there are transfer rolls 8 and 9 which apply liquid to the surfaces of the pad rolls.
In the embodiment shown in FIGURE 1, the transfer rolls 8 and 9 are rotated in the same direction as the pad rolls 2 and 3; thus the surfaces of the transfer rolls and the pad rolls move in opposite directions where these rolls come together. The transfer rolls 8 and 9 may be covered with hard rubber, but preferably they may ha~e metal sur~aces.
Below the transfer rolls 8 and 9 therP are meter rolls 10 and 11 which are partially immersed in li~uid treating agents in pans 12 and 13. The meter rolls travel in the opposite direction from transfer rolls ~ and 9 so that the surface of the transer and meter rolls travel in the same direction where they come together. The meter rolls may be of the same construction as the transfer rolls.
In operation, all of the rolls are rotated by motors or other power means (not shown in the drawing) through sprocket chains as shown. However, only one of the pad rolls is driven b~ a motor; the other pad roll is mounted so that it can rotate ~reely, 1~7~f~

but it is driven by the first pad roll through the fabric. Each meter roll lifts liquid as it emerges from the pan in which it is partially immersed, in the form of a film of liquid on the surface of the meter roll. At the junctures of ~he meter rolls and the transfer rolls, a clearance is provided which allows a thin film of liquid to be transferred from the meter rolls to the transfer rolls. Usually, the clearance will be 0.004 to 0~011 inch. Howeverl larger clear-ances may be used, for example 0.020 to 0.030 forheavier application rates, e.g., latex applied to a carpet back. At the juncture of the transfer rolls and the pad rolls, a similar transfer occurs to form thin films of liquid on the pad rolls. At that location, the transfer roll preferably is in contact with the pad roll or pressed into the pad roll 0.004 or 0.005 inch more or less. However, if very light application rate is desired, it may be desirable to space the trans-fer roll from the pad roll; this is rarely if ever necessary.
By adjusting the clearance between the rolls and the relative speeds of the rolls~ the thickness of the films of liquid on the pad rolls can be adjusted.
Preferably, the pad roll runs 0.5 to 4 times the surface spePd of the transfer roli and the meter roll runs 0.5 to 4 times the surface speed of the tran~fer roll. For heavier~fabrics, in general, the meter and the transfex rolls are turned more slowly so that more liquid is applied to the pad rolls and transferred to the fabric. The speedæ of the pad roll may be increased still further, relative to the transfer roll and a surface speed ratio of 7.5 to 1 may be used in some cases. Higher pad roll speeds reduce the thick-ness of the film of liquid on the pad roll and thus the amount of liquid applied. However, caution must 10~

be taken because in some cases, surface tension may break the fllm, depending on the rheology of the particu-lar liquid. The surface speed of the metering roll preferably should be at least 75 feet per minute. On the other hand, excessive metering roll speed should be avoided since it will cause slinging of the liquid.
The maximum speed depends on the rheology of the liquid and the diameter of the metering roll, as smaller rolls and less ~iscous liquids are more vulnerable to slinging.
It has been found desirable that the metering roll be rotated at sufficient speed to maintain a flooded nip, i.e., the space between the metering roll and the transfer roll must be filled at all times. The necessary rotational speed is easily recognized by the back flow pattern on the metering roll during opera-tion. For a given fabric, the pad roll to transfer roll surface speed ratio and the metering roll to transfer roll surface speed ratio can be adjusted to achieve the desired application rate while maintaining the requisite metering roll speed. As an illustration, in a machine with 18" diameter pad rolls and 12" steel transfer and meter rolls the following conditions achie~e similar metering roll rotational speeds at operating speeds of 100 yards per minute and 60 yards per minute:
Fabric weight: 9.50 oz./s~.yd. Wet pickup: 12.5%
Roll space - Metering to Transfer Roll 7 mils at 100 ypm at 60 ypm Ratio of pad roll speed to transfer roll speed (surface speed ratio) 1.60 1.30 Ratio of meter roll speed to transfer roll speed (surface speed ratio) 1.75 2.35 Meter Roli Rotational Speed (RPM) 104 104 ~L0~7~4 C~ntrol of both the ratio of surface speeds which, in conjunction with the roll spacing, determines the amount of mix applied to the fabric and control of rotational speed to accommodate to machine operating conditions, mix viscosity and wetting characteristics allows extreme latitude in establishing and optimizing applicati~n conditions for a given fabric.
FI~URE 2 schematically illustrates an alterna-tive embodiment adapted to apply smaller amounts of li~uid to the fabric. This embodiment differs from the embodiment in FIGURE 1 in that the directions of rota-tion of rolls 8, 9, 10 and 11 all are reversed. In general, the amount of liquid applied to the pad rolls is less in this embodiment.
An important feature of the present invention is the use of soft pad rolls of relatively large diam-eter. In general, it has been ~ound desirable to use rolls having an exterior layer of elastomeric material which is resistant to the treating liquid. The rubber may be, for example, neoprene or natural rubber, depending upon th~ composition of the liquid. ~he elastomeric material preferably is es~entially solid, as distinguished from porous, cellular or foamea - elastomers. Furthermore, the surface of the elastomer is preferably smooth and level. Thus, the process does not function by absorbing li~uid in a porous roll covering but by carrying a thin layer of liquid on the surface of the pad roll.
It will be reali2ed that small surface or interior imperfections which sometimes occur in rubber products may be present. In addition, while a foamed or cellular elastomer is neither necessary nor desir-able, a smooth or continuous-surfaced foamed elastomer may be u~ed, provided it possesses the necessary stiffness.

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g The soft pad rolls usually will have an exterior diameter of 12 to 24 inches although smaller and larger rolls may be used. The hardness of the rubber layer should be less than about 75 durometer and preferably more than 30 durometer Shore A. Rubber which is too hard requires too much pressure to func-tion and, therefore, will crush the fabric. Rubber which is too soft may not be durable.
Another important featuxe of the invention resides in the pressure applied between the pad rolls.
The applied force is chosen depending upon the hardness of the rubber covering on the rolls and the thickness of that covering. The force should be sufficient to provide a contact zone extending at least 1/2 inch along the fabric. In actual practice, the contact zone has been 3/4 to 1 inch long and, although not essential, that length is much preferred. The applied pressure and the length of the contact zone depend, to some extent, on the effect desired in the process, the construction of the fabric and the weight of the fabric; these factors can be determined by simple experimentation. Generally these rolls are pressed against opposite sides of the fabric with a force of at least about 10 psi, although a contact pressure of at least 25 psi is preferred. Usin~ a 45 durometer (Shore A) rubber roll, it has been ~ound that the length of the contact zone and the effectiveness of the process does not vary much using contact pressures of 20-350 psi, so long as there is sufficient pressure for the driven pad r~11 to drive the other pad roli. With a pressure of 50 psi, the contact zone was 3/4 inch and at 350 psi it was about 1 inch. The contact pressure depends on the hardness of the rubber. It is found in practice that the presssure is greatest at the ends o~
the rolls and less along the central portions.

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~10-The pad rolls normally comprise a rubber covering on a steel roll, since this provides a more durable roll. The covering may be as thin as l/8 incn.
As the fabric moves between the pad rolls, the rubber is flexed as it is flattened in the contact æone causing a manipulation of the fabric. While not fully understood, it is believed that some flexing or stretching takes place in the fabric which moves fibers relative to each other. A standing wave is believed to form along the surfaces of the rolls and possibly along the fabric. The action forces liquid through the fabric, from the surface to which it is applied, toward or to the opposite surface. The depth of penetration depends, to some degree, on the roll pressure, the amount of liquid applied, the length of the contact zone 6 and the weight and construction of the fabric.
However, the liquid penetration is distinctly different from the surface application observed with hard rubber rolls.
An important advantage of the present invention is the abili~y to apply very small amounts of liquid to a fabric and yet insure full penetration. In appropriate circum~tances, it is possible to apply sufficiently little liquid, for example, dye liquor, that the fabric need not be dried before it is wound, resulting in substantial savings in energy. In other cases, where some drying is necessary, the amount of energy required i8 much less. For example, drying and curing time for application of durable press resins to bedshee* ~abric can be reduced from 90 seconds to 13 seconds.
Another advantage of the process is that it makes it possible to avoid migration of treating agents to the surfaces of the textile. In contrast, when textiles are saturated with water soluble dyestuffs or 7~

durable press resins, there is a tendency for the agents to migrate to the surfaces of the textilP during drying. In accordance with the present invention, it is possible to apply just enough water with the treating agent to distribute water within the fib~rs as inter-stitial water, without filling the capillaries between fibers. Typically, this will involve wet pick-ups of say 10-20% of the dry fabric weight. At such low appli-cation rates, water and the water soluble treating agents are distributed substantially uniformly through the fabric, but they do not migrate to the surface. By contrast, with conventional padding, it normally is difficult to obtain wet pick-ups less than 60%.
The present invention is applicable to a wide ~ariety of textiles including natural, man-made and synthetic fibers. Natural fibers to which the invention may be applied include regenerated cellulose (rayon), cellulose acetate and cellulose triacetate. Synthetic fibers which may be used include polyamide (nylon 6 and 66), polyester (polyethylene terephthalate), polyolefin (polyethylene and polypropylene), acrylic (polyacrylo-- nitrile) and modacrylic, as well as various blends.
The fabrics may be nonwoven fabrics, flocked fabrics or woven or knitted fabrics made with continuous filament and~or spun yarns. The invention may be used with ~abrics having a weight of, e.g., 1 to more than 24 ounces per square yard. The.invention also is applic-able to warp sizing.
A wide variety of treating agents may be applied, including all finishing agents commonly applied to textiles, both water soluble and water-dis-persed, such as bleach, dyes, sizes, various resins and water repellents.
Interesting effects can be achieved because of the controlled penetration produced by the present l~9t7~9,~

invention. For example, it is possible to apply two different treating agents with the respecti~e pad rolls, even though those treating agents are not compatible in a single bath. Thus, in applying a durable press resin, one impregnates with a solution containing both resin and catalyst. However, in some cases, the ca~alyst can cause premature polymerization of the resin. By separately applying the resin and catalyst solutions, in accordance with the present invention, the resin and catalyst do not contact each other until - they have been applied to a fabric. Furthermore, through the application of diminished amounts of resin, it is possible to stabilize the fabxic dimensionally and achieve some crease resistance without making the fabric stiff or boardy. Alternatively, the resin and catalyst can be applied together from one side of the fabric at a very low application rate. If the applica-tion rate is su-fficiently low, having regard to the weight of the fabric, the resin can penetrate suffici-ently to stabilize the fabric dimensionally withoutaffecting-fibers on the opposite surface. While this ~ procedure surrenders the advantage of separately applying catalyst and resin, the natural hand of, say, a cotton fabric can be preser~ed e~en though the fabric possesses the dimensional stability and crease resist-ance of a duxable press fabric.
In another embodiment, in which, for example, a d~nim fabric is treated with resin, only a ~ery light application of resin is made from one side of the fabric. For instance, the resin application may be a 5% wet pick-up of a 40~ solution o resin. As a result of the limited penetrat~on of resin, the resin fixes the fabric near one suxface and stabilizes the dim~n-sions of the fabric. Howe~er~ the resin does not penetrate deep in~o the interior o~ the fabric. This ~C~97l)~

is important in the case o denim fabrics which the public desires to fade during laundering. In other words, the resin does not prevent desired washdown of dyes, but it does pro~ide dimensional stability in the form of resistance to shrinkage.
Other interesting eff~ts can be achieved by applying dyestuffs with the process of the present invention. For example, two different dyestuffs can be applied from opposite sides of fabrics at controlled rates and in sufficient quantities to penetrate through the fabric. Unlike continuous dye processes involving exhaustion of dyes into a fabric, it is possible to provide continuous control of the color of the fabric and assure that each successive len~th of fabric has the same color.
Another advantage of the present invention is observed in the treatment of knit fabrics which are constructed of ayed yarns. Whereas some treatments of yarn dyed fabrics may cause pattern distortion, the soft pad rolls used in the present invention minimize or avoid this difficulty.
The following examples illustrate the invention.
Unless otherwise indicated, proportions are on a - weight basis. The designation "M to T roll space"
refers to the space between the meter and transfer rolls. The designation UP/T" is the ratio of the sur~ace speed of the pad roll to the surface speed of the transfer roll. ~he designation "M/T" is the ratio ~ the surface speed o~ the meter roll to the surface 3a speed o~ the trans~er roll. The references to "~ace"
and "back" relate to the face and back of the fabric~
the compositions applied respectively to the ~ace and back of the fabric, and the rolls which make the respective applications. In these examples, steel meter and transfer rolls were used. The pad rolls were :1(35~

in contact with the transfer rolls. The transfer and meter rolls were lO inches diameter, 72-inch face. The pad roll was 18 inches diameter, including a l-inch thick layer of 45 durometer rubber (Shore A) over a steel shaft. Pressures between the pad rolls were above 20 psi and sufficient for the driven pad roll to drive the other pad roll through the fabric. Unlesc otherwise indicated, the fabric speed was 30 yards per minute.
The test procedures utilized were as follows:
Grab Break.......... ANSI/ASTM Dl682-64 (Reapproved 1975) See "Grab Tests, G") Elmendoxf Tear...... ANSI/ASTM D1424-63 ~Reapproved 1975) Appearance Rating.. AATCC-124 Flex Abrasion...~.. ANSI/ASTM Dl175-71 Flexing and Abrasion Method ~0~7() ~4 Sample 1 Fabric: Indigo dyed denim, desized, 12.25 oz./sq.yd.
prepared for finishing.
Machine Settings:
. Face Rolls Back Rolls M to T roll space 5 mils 5 mils P/T 1.20 1.50 M/T 1.20 . 1.95 % Wet pickup 12.5 7 Mixes Applied:
Fabric Face:
Emulsified fatty alcohol softener 3.75 Fabric Back:
Acrylic resin emulsion 20%
Glyoxal-urea-formaldehyde condensate 10%
High density polyethylene emulsion 1.7%
Magnesium salt catalyst 6~7%
Long chain alcohol ethylene oxide condensate wetting agent ` 0.38%
25 Drying and ten~ring. 18 seconds at 275F.
Mechanical compressi~e shrinkage a~ter drying and tentering: 4-1/2 inches/yard '~
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2 was considered excellent.

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Sample 1 Fabric: Corduroy, 50% polyester/50% cotton warp, 100% cotton filling 9.25 oz./sq.yd.
Machine Settings:
Face Rolls Back Rolls - M to T roll space 5 mils- 5 mils P/T 1.20 1.20 M~T 1.30 2.40 % Wet pickup 15 10 Mixes Applied:
abric Face:
Emulsified fatty alochol softener 3.3%
Polyol defoamer 0.05%
Fabric Back:
Acrylic resin emulsion 15.6 Glyoxal-urea-formaldehyde condensate 15.6%
High density polyethylene emulsion 7.24 Magnesium salt catalyst 7.2%
Long chain alcohol ethylene oxide condensate wetting agent 0.375%
Polyol defoamer 0.05%
Drying 18 seconds at 300F.
Curing ~0 seconds at 325F.
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-2~-Improved filling shrinkage control and improvad appearance with a maintenance of filling breaking strength were particularly important for these fabrics.
With corduroy fabrics it was found that :~-softness of hand could be adjusted readily by control ofthe amount and type of softener applied to the face and choice of acrylic resin emulsion applied to the back.
In a further comparison it was found that corduroy treated in accordance with the invention could be dried and cured in 30 seconds at 380F by simply passing through a tenter frame. In order to dry only a saturation padded fabric at the same speed it was necessary to employ a high capacity predryer.
Other corduroy fabrics, including 100% cotton corduroy and corduroy containing 50% polyester, 50%
cotton yarns in both warp and filling, have been processed satisfactorily by the same method.

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'' ' ~(~9 Fabric: 11 oz/sq.yd. cotton denim.
Machine Settings:
Sample Face Rolls M/T space mils 5 5 5 P/T 2~00 1.60 1.20 M/T 2.25 1.70 1.70 Back Rolls M to T space, mils 6 6 6 P/T 1.60 1.20 1.00 M/T 2.20 1.35 1.15 Wet pickup anticipated Face 5% 7.5% 10%
Back 10% 15% 20~
Mixes Ap~lied: -Face Emulsified fatty alcohol softener 2.5%
Back Emulsified acrylic polymer resin 10%
Glyoxal-urea-formaldehyde condensate 15%
High density polyethylene emulsion,1.7%
Zinc nitrate catalyst solution 2.8%
Linear alcohol ethylene oxide condensate wetting agent 0.38%

The mixes were applied and the ~abrics were dried on a tenter frame in 18 seconds at 275F. -The fabrics were compressi~ely shrunk as a final finishing step.

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~7()5~4 Another set of ~amples were prepared from this fabric in which the mix components were varied to achieve maximum softness o~ the finished fabric and to determine effects on fabric p~ysical properties.
5 Machine Settings: 7-4 and 7-5 Face ~ to T roll space 5 mils P/T 1.30 M/T 1.50 Back M to T roll space 6 mils P~T 1.15 M/T 1.25 Wet Pickup, Face 10%
Back 15%
Mixes:
15 Face Mix Emulsified ~atty alcohol softener 5%
Bac~ Mixes 7-4 7-5 Fmulsified acrylic resin 6.7% 3.4~
Glyoxal-urea-~ormaldehyde 13.4% 13.4%
High density polyethylene emulsion 1.7% 1.7%
Zinc nitrate catalyst6.7% ~ 6.7%
Wetting agent 0.38~ 0.38%
The ~abric was dried 12 seconds at 275F and then compressively shrunk.
25 Fabric Properties 7-4 7-5 Grab Break, lb, W X F 166 X 78 168 X 88 Elmendorf Tear, lb, W X F25.5 X 12.8 23.5 X 14.1 Appearance Rating 4.0 3.9 Shrinkage . 30 5 Home Launders0.3+ X 0.1 1~2 X O.3 : Flex Abrasion cycles 3940 X 1900 3860 X 2850 :~.()9~ 4 -~4-Although the hand was extremely sot, excessive catalyst caused some deterioration in fabric strength.
Note that all curing occurs within the period o time that the abric is heated on the drying cylinder of the compressive shrinkage machine.
Total time for drying and curing of the fabric may be 18 seconds or less depending upon abric weight, steam pressure and cylinder dimensions, although the time may ~e increased if desired.

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~S''7~4 ExAMæLE 4 Fabric: Light weight denim fabric 9.O oz./sq.yd.
Indigo dyed.
Machine Settings Face Back M to T roll space 5 mils 11 mils P/T 1.65 1.55 M/T 2.35 2.40 Wet pickup 7.5~ 17.5%
Face Mix: Emulsified fatty alcohol softener - 4%
Long chain alcohol ethylene oxide wetting agent - 0.25%
Back Mix: Emulsified fatty alcohol softener - 2%
Acrylic resin emulsion - 8%
Glyco}-urea-formaldehyde resin - 8%
Long chain alcohol ethylene oxide - wetting agent - 0.25%
Zinc nitrate catalyst - 1.7%
Operational speed: 100-110 yards per minute.
Drying time: 16-18 seconds ~predryer eliminated~.
Compressive shrinkage: 4.5 inche~ per yard.
The finished denim fabrics were characterized by a soft, supple hand, good strength retention, good laundered appearances and excellent shrinkage control.
Of primary importance was the fact that the finished denim fabri~s did not exhibit any growth, which causes increased shrinkage, in storage. This is a common characteristic o~ regular production of soft denims.
The operating speed was ~aster ~han ~ormal for this ~abric when saturation padded, the normal cpeed being 55 to 60 yards per minute and drying time was 30-33 seconds plus approximately 20 seconds in a predryer.

10~094 EXA~PLE 5 Fabric: Type 180 50~ cotton/50% polyester sheeting 3.85 oz./yd2.

Sample 5 Machine Settings: 6 6-B 6-C
M to T space 5 mils5 mils 5 mils P/T . 3.002.50 1.65 M/T 3.303.20 3.00 Wet pickup, % 15 20 30 Ratios were the same for face and back rolls wet pickup was the same for face and back.
The finishing mi~ Ifrcoe aA~ back) contained:
Alkyl carbamate formaldehyde condensate 18%
Magnesium phosphate catalyst 6.4 Linear alcohol ethylene oxide condensate 0.5 Emulsified fatty alcohol softener 2.0 Drying time 12 seconds at 350F.
~ hree replications were made using a different machine setting to obtain the same wet pickups with the same alkyl carbamate fi~ish, as follows:

~ to T space 5 mils 5 mils 5 mils : P/T 2.85 2.35 1.85 M/T 3.70 3.35 2.65 25 Wet pickup, % 15 20 30 .
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On analysis of the fabrics for formaldehyde content the averages found were:
Ratio Ratio of of Wet Formaldehyde Pickup Fabric Content to Indicated to 15~ Formaldehyde Content at Wet Pickup Pickup Content, % 15% Wet Pickup 15% 1.0 0.32 1.0 20% 1.33 0.42 1.31 10 30% 2.0 0.65 2.0 Fabric Performance Properties:
Indicated Appearance Rating Shrinkage, W X F, %
Wet Pickup A~C-124 -- 5 Home Launders ~ .
15% 3.1 2.0 X 0.7 15 20% 3.4 1.7 X 0.6 30% 3.8 1.4 X 0.6 ExAMæLE 6 Fa~ric: Striped tubular cotton jersey knit weighing 4.05 oz./sq.yd.
20 Machine Settings:
M to T roll space both sides 4 mils P/Tl, P/T2 2.75 Ml/Tl r M2/T2 Wet pickup, % 5 Mix appl ed on both s_des:
25 High density polyethylene emulsion 5%
Diethylene glycol 5%
: Phosphated alkyl phenol ethylene oxide condensate wetting agent 0.44 Drying: None required since the amount of moisture applied was less than normal regain for the fabric.

-2~-Processing: The fabric processed smoothly without distortion. The stripes remained true and there was no slippage between surfaces of the fabric.
Moisture content found: Side l 4.5%
Side 2 4.7 Average 4.6%~
Estimated total add on 5.1%

Application of a dip solution to one side of a fabric. A bleached percale sheeting of 50% polyester and 50% cotton was processed to determine uniformity at application at several settings.
Parameters: Fabric weight - 3.70 oz./yd.2, Overbite, transfer roll to pad roll - 8 to 11 mils 15 Mix Applied: % by weight B ! Triton X-35 twetting agent) 0.25 Griffwet NB-106 (wetting agent) 0.25 Nylomine Green C~3G (Dye) 0.20 Diethylene glycol (lubricant) 1.0 M to T
Sample P/T M/T Roll Space % Wet Pickup l 2.00 3.05 4 mils 10 2 1.40 1.90 4 20 3 1.20 1.30 4 30 The niP Pressure between the Pad rolls was aP~roximatelY 55 lbs./linear inch. The fabric was Processed at 60 FPm. It was dried 18 seconds at 350F
on a tenter frame.
le ~r?ark~
~' ~

1097U~4 -2~-Sample uniformity was evaluated visually as follows:
Sample #l - Some barre' ef~ects due to variation in fabric construction were visible while the fabric was wet but were not apparent in the dry ~abric.
Sample #2 ~ Uniform application.
Sample ~3 - Uniform application side to side, end to end and face to back.
The depth of color increased uniformly from Sample 1 through Sample 3. This example illustrates that color can be applied uniformly through a fabric at }ow moisture add on and that the usual procedure of saturation followed by squeezing out o~ excess solution is not necessary for color uniformity. An important point is that the total water content o these fabrics i~ far less in every case than conventional saturatio~
padding in which solution pickup is generally 60%
greater a~ter excess solu~ion is squeezed from the fabric.

In a similar series of samples in which a blue dye solution was applied to one side o sheeting fabric and a yellow dye solution to the other side of the fabric and wet pickup on each side was varied from about 5% to 30% on the weight o~ the fabric, it was ~ound that a green colored ~abric was usually produced.
The shade and depth o~ color varied depending upon the relative amounts of blue and yellow dye solutions ~ applied and the total amount applied. At the lowest wet pickup on each side~ however, the fabric was bicolored, that is one side was yellow by reflected light. By transmitted light the ~abric was green.

Application of dyes at low wet pickups to oth~r fabrics gave some very novel efects. On a terry fabric similar to terry toweling, it was possible to dye the terry loops different colors on each side of the fabric. The depth of penetration o~ the color into the towel loops was controlled by adjusting the wet pickup of dye solu-tion of each side of the fabric. The colors were applied simultaneously to both sides of the fabric.
Bicolored fabrics have been produced by simul-taneous application of different colors to each side ofthe ~abrics as described by restricting wet pickup on each side even where the dye solutions are compatible.
Another method of obtaining bicolored fabric is to use mutually incompatible solutions. For example a dye solution containing 2% by weight of disodium hydrogen phosphate was applied to one side of a fabric, a second dye solution containing .2% by weight of zinc chloride was applied to the other side of the fabric. Precipi-tation at the interface effectively prevented mixing of the dyes and provided a bicolored fabric. Wet pickup on each side was 15% based on the weight of the fabric.
Many other pairs of incompatible reagents which precipi-tate or form a barrier on contact may be used. The relative amounts of each solution applied may be varied to control the effective dividing line between solutions in the fabric. The use of mutually reacti~e or incom-patible solutions is not restricted to color.
Many other fabrics have been proce~sed by application of ~he same or different formulations to face and back of fabric. The amount applied to face and back has been and can be varied at will over a wide range. Minimal amounts of material can be applied.

~0~

The fabrics processed have included light weight sheeting and heavy denim, and corduroys of all cotton and polyester/cotton fiber blends, brushed fabrics have been processed to achieve a soft smooth fabric face and, simultaneously, excellent wash performance. Because the fabric has such short contact with the transfer padding machine, mechanical distortion in processing is reduced appreciably. This allows processing of delicate or unstable fabrics such as knits, corduroys, brushed fabrics and soft fabrics without distortion.
Because the invention provides control of moisture content, significant increases in output are possible. An increase in operating speed from the range of 55-60 ypm up to 110 ypm on a denim fabric while simultaneously eliminating the necessi~y for a predrying step was achieved. Fabrics have been processed satisfactorily at speeds such that the drying time has been reduced to 10 seconds or less. It is apparent that proper utilization of the transfer padding machine can eliminate a significant part of the fabric drying load and provide unique finished fabrics.
Warp sizing has been applied to fabric as part of a study to determine the adaptability of the machine to y~rn slashing. Uniformity and distribution of the size within sized fabrics appeared to be much improved as compared to slashed yarn. Again drying loads in yarn slashing can be reduced appreciably.
A very novel aspect of the machine is the ability to control wet pickup through variation in suxface speeds of the metering and transfer rolls.
Precise control of these roll speeds has bsen obtained by both mechanical drives and electrical drives.
Coupled with the ability to change roll spacing readily ~3~'7 through fine pitch adjusting screws, there is available an almost infinite selection of machine conditions to control application of mixes to fabrics and yarns.

Claims (19)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A process for applying liquid treating agents to textiles comprising moving said textile between a pair of soft elastomer rolls, rotating one of said soft elastomer rolls, pressing said soft elastomer rolls against the opposite sides of said textile with sufficient pressure that the other soft elastomer roll is rotated by said one roll, and applying a liquid treating agent for said textile to at least one of said soft elastomer rolls for application to said textile.

2. A process as set forth in claim 1 in which at least the outer portions of said soft elastomer rolls have a hardness of 30-75 durometer on the Shore scale.

3. A process as set forth in claim 2 in which at least the outer portions of said soft elastomer rolls have a hardness of about 45 durometer on the Shore A scale.

4. A process as set forth in claim 1 in which the pressure between said soft elastomer rolls is sufficient to flatten them along a contact zone.

5. A process as set forth in claim 4 in which the contact zone is at least 1/2 inch long, along the direction of movement of the textile.

6. A process as set forth in claim 1 in which the textile is a fabric.

7. A process as set forth in claim 6 in which the fabric is a woven or knitted fabric.

8. A process as set forth in claim 1 in which the pressure between said soft elastomer rolls is 20-350 psi.

9. A process as set forth in claim 1 in which said liquid treating agent comprises a dyestuff.

10. A process as set forth in claim 1 in which said liquid treating agent comprises a textile resin.

11. A process as set forth in claim 1 in which liquid treating agent is applied to both of said soft elastomer rolls.

12. A process as set forth in claim 11 in which different liquid treating agents are applied to the respective soft elastomer rolls.

13. A process as set forth in claim 12 in which the respective liquid treating agents are chemically reactive with each other.

14. A process as set forth in claim 1 in which said liquid treating agent is applied to said at least one soft elastomer roll by applying the liquid treating agent to a transfer roll which is rotated parallel to said at least one soft elastomer roll and with its surface adjacent said at least one soft elastomer roll.

15. A process as set forth in claim 14 in which said liquid treating agent is applied to said transfer roll by applying it to a metering roll which is rotated parallel to said transfer roll, the surface of the metering roll being adjacent to but spaced from said transfer roll, the rate of application of said liquid treating agent to said at least one soft elastomer roll being controlled by adjusting the spacing between said metering roll and said transfer roll and the relative speeds of the rolls.

16. A process as set forth in claim 15 in which said metering roll is partially immersed in said liquid treating agent.

17. A process as set forth in claim 15 in which said transfer roll is in contact with said at least one soft elastomer roll.

18. Apparatus for applying liquid treating agents to textiles comprising a pair of soft elastomer rolls mounted for rotation on substantially parallel axes with their surfaces adjacent each other, means for rotating one of said elastomer rolls, a transfer roll mounted for rotation on an axis substantially parallel to the axes of said elastomer rolls with the surface of the transfer roll adjacent the surface of one of the elastomer rolls, a meter roll mounted for rotation on an axis substantially parallel to the axes of said elastomer rolls with the surface of said meter roll adjacent to but spaced from the surface of said transfer roll, means for applying liquid to the lower portion of the surface of said meter roll, and means for rotating said meter and transfer rolls so that their surfaces move in the same direction at the place where their surfaces are adjacent to each other, the spacing between said meter and transfer rolls and the speeds at which said rolls are driven being adjustable, whereby a thin film of said liquid may be applied to the surface of said one elastomer roll, the thickness of said film depending on the speeds of said rolls and the space between them.

19. Apparatus as set forth in claim 18 in which said means for applying liquid comprises a pan of said liquid, said meter roll being partially immersed in said liquid.