EP0177277B1 - Method and apparatus for patterning substrates - Google Patents

Method and apparatus for patterning substrates Download PDF

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Publication number
EP0177277B1
EP0177277B1 EP85306852A EP85306852A EP0177277B1 EP 0177277 B1 EP0177277 B1 EP 0177277B1 EP 85306852 A EP85306852 A EP 85306852A EP 85306852 A EP85306852 A EP 85306852A EP 0177277 B1 EP0177277 B1 EP 0177277B1
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EP
European Patent Office
Prior art keywords
stream
fabric
fluid
reed
channel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP85306852A
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German (de)
English (en)
French (fr)
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EP0177277A1 (en
Inventor
Charles Everage Willbanks
Franklin Sadler Love Iii
Michael William Gilpatrick
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Milliken Research Corp
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Milliken Research Corp
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Priority to AT85306852T priority Critical patent/ATE58563T1/de
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00—Making patterns or designs on fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00—Making patterns or designs on fabrics
    • D06C23/04—Making patterns or designs on fabrics by shrinking, embossing, moiréing, or crêping

Definitions

  • This invention relates to a method and apparatus for patterning a substrate placed against a support by directing at least one stream of treating fluid at the substrate surface and interrupting and re-establishing contact between said treating fluid stream and said surface in response to electrically encoded pattern information.
  • a method and apparatus are described in EP-A-0 099 639, in which streams of hot pressurized fluid are discharged into the surface of a textile substrate to impart visual surface changes, particularly by bubble formation within individual constituent fibers.
  • the hot fluid is passed through a series of parallel passages or a single continuous slot and is interrupted, in accordance with patterning information, by streams of cool air directed transversely into the slot or passages to locally block and stop the passage of heated air through respective passages or portions of the slot.
  • the method of this invention embodies or makes possible the above capabilities and is characterised in that said at least one stream of treating fluid is directed at the substrate surface under a peak dynamic pressure in excess of 33 p.s.i.g. (2068 kPa).
  • the method can be carried out in various forms of apparatus as defined in Claims 11, 14 and 17 hereinafter.
  • high velocity streams of treating fluid for example, water
  • a fabric which is comprised of substantially continuous yarns which are interlaced in a repeating configuration to physically modify the surface appearance or texture thereof in a pre-determined pattern.
  • fluid stream size, stream velocity, nature of the fabric support surface, etc. many different and unexpected patterning effects may be achieved. For example, textural differences which mimic the effects of a Jacquard-type weaving process may be achieved, but with much greater speed and at much lower cost than is associated with such a specialized weaving process.
  • patterned fabrics when used in conjunction with various fluid stream manipulation means and methods disclosed herein, can be employed to pattern fabrics with patterns which are electronically stored or generated.
  • stream manipulation systems in association with the instant invention, patterned fabrics may be generated which have arbitrarily chosen pattern repeat lengths, and the patterns placed on the fabric may be changed without significant down time for the patterning apparatus and without the necessity of having an inventory of pattern "masters" which occupies significant storage space.
  • FIG. 1 schematically depicts an apparatus which may be used to practice one embodiment of the process and generate the products of this invention.
  • Pump 8 is a pump capable of pumping the water or other desired working fluid at the desired rate and pressure. If a single liquid stream is used, the pump should be capable of delivering a single stream having a minimum cross-section dimension within the range of about 0.003 inch to about 0.03 inch, at dynamic pressures ranging from about 300 p.s.i.g. to about 3000 p.s.i.g. (i.e., water stream velocities ranging from about 200 f.p.s.
  • pump 8 is connected to a source 2 of the desired working fluid, e.g., water, via conduit 4 and filter assembly 6.
  • desired working fluid e.g., water
  • Filter assembly 6 is intended to remove undesirable particulate matter from the working liquid which could clog the various orifice assemblies discussed in more detail below. Other, additional filters may be used, and are discussed below.
  • the high pressure output of pump 8 is fed, via high pressure conduits 10 and 10A, to high velocity fluid orifice assembly 12.
  • Orifice assembly 12 in simple form, may be merely a suitable termination of conduit 10A having a single orifice of the size which will generate a fluid stream of the desired cross-sectional shape and area, and which will operate safely at the desired pressure, as depicted in Figure 2.
  • Conduits 10 and 10A may be any suitable conduit capable of safely accommodating the desired fluid pressures and flow rates, and having sufficient flexibility or rigidity to permit orifice assembly 12 to be positioned as desired with respect to the substrate to be treated.
  • roll 20 Situated in close proximity to orifice assembly 12 is roll 20, over which the textile fabric to be patterned is placed.
  • roll 20 has a solid, smooth, inflexible surface (e.g., polished aluminum or stainless steel); a roll having a specially treated or formed surface may be useful in achieving certain special effects on selected substrates. It has been found, for example, that use of a contoured roll surface may result in patterning effects corresponding to the roll surface contours on the substrate.
  • fabric 25 Associated with roll 20 is fabric 25, which may be in the form of a fabric section which is wrapped tightly about the circumference of roll 20 and securely attached at both ends, as depicted in Figure 1, or which may be in the form of a continuously moving web which is positioned against a portion of roll 20, depicted in subsequent Figures at 26.
  • Figure 1 shows a diagrammatic side view of a texturing and patterning system in which an orifice assembly 12, which produces a single high velocity fluid jet 18, is associated with a traversing table 14.
  • Table 14 permits orifice assembly 12 to be moved, in a precisely controlled and reproducible manner, parallel to the axis of roll 20, around which is affixed a section of fabric 25, perhaps in the form of a sleeve or a short section of fabric which is securely fastened at both ends about the circumference of roll 20.
  • Orifice assembly 12 may be constructed by installing a high pressure cap 13 having a single orifice of the proper size on the end of a suitable high pressure conduit 10A, as depicted in Figure 2.
  • a high pressure cap 13 having a single orifice of the proper size on the end of a suitable high pressure conduit 10A, as depicted in Figure 2.
  • more elaborate orifice assemblies may be used as well, as will be discussed below.
  • valve fluid 16 Associated with conduits 10 and 10A is remotely actuated valve fluid 16, which valve is preferably installed in close proximity to orifice assembly 12 so as to minimize the length of conduit 10A between valve 16 and orifice assembly 12.
  • Valve 16 may be actuated electrically, pneumatically, or by other means.
  • valve 16 comprises an electrical solenoid valve of the type marketed by the Skinner Valve Company, a division of Honeywell, Inc., of Minneapolis, Minnesota, as Model V52H. This valve is installed upstream of orifice assembly 12, in a conventional manner such as to control the flow of fluid in conduit 10A.
  • a working fluid e.g., water
  • a working fluid e.g., water
  • pump 8 pumped by pump 8 from fluid source 2, through filter means 6, to valve 16.
  • valve 16 is made to open, e.g., via an electrical or pneumatic command signal, and high pressure water is allowed to pass via conduit 10A to orifice assembly 12, where a thin, high velocity jet 18 of water is formed and directed onto the fabric 25.
  • an appropriate electrically or pneumatically transmitted instruction causes valve 16 to close.
  • Positioning the desired areas of fabric surface under the jet 18 is achieved by proper coordination of rotation of roll 20 and translation of traversing table 14, which preferably may be accomplished by computer control.
  • a computer may be used to generate on/off instructions to valve 16 in accordance with pre-programmed pattern data. It is contemplated that roll 20 may be made to rotate continuously while traversing table 14 moves relatively slowly, in incremental linear steps, along the axis of the roll, or, preferably, roll 20 may be made to move intermittently, while traversing table 14 sweeps across the fabric face for each incremental rotational movement of roll 20. If the latter technique is employed, fabric 25 may be in the form of a web 26 travelling over roll 21, as shown in Figures 3 and 4, which better lends itself to commercial production methods.
  • a multiple jet array orifice assembly 32 is situated in close proximity to the surface of fabric web 26, as web 26 passes over roll 21.
  • Array assembly 32 may be sufficiently wide to extend entirely across web 26, or may comprise a fraction of the width of web 26. In the latter case, a traversing table or other means may be used, as discussed above, to obtain full-width coverage.
  • a separate remotely actuatable valve, designated at 16A Associated with each orifice in array assembly 32, and situated in the corresponding conduit 10A, is a separate remotely actuatable valve, designated at 16A, which serves to interrupt or control the stream of high velocity fluid emanating from its respective orifice in array assembly 32.
  • valves can be of any suitable kind, e.g., electrical, pneumatic, etc., and may be insstalled in any satisfactory conventional manner which will allow safe and positive control of the pressurized fluid.
  • a hydraulic accumulator or ballast tank 30 Inserted between pump 8 and the array of valves 16A is a hydraulic accumulator or ballast tank 30.
  • pump 8 may be specified at a somewhat smaller capacity than would otherwise be the case. Peak, short term demands for high pressure liquid, as when all jets are firing for a given short period of time, may be met by the capacity stored or accumulated in tank 30.
  • Figure 7 depicts a section view of array assembly 32, taken perpendicular to the surface of roll 21 and bisecting the orifices in assembly 32.
  • Orifice block 34 is drilled and fitted with tubes 35 which extend beyond block 34 and which are securely connected with respective supply conduits 10A.
  • Orifice plate 33 is drilled with converging passages 36 which form collectively an array of jets.
  • a stencil is interposed between a single jet or an array of jets and the fabric 25 to interrupt the liquid stream, in place of the valves disclosed above.
  • a sleeve-type stencil 40 comprised of stainless steel, suitable plastic, or other suitable material which serves to mask areas of the fabric which are not to be treated, is placed in fixed relationship over the fabric segment 25 which is attached to roll 20.
  • a traversing means 14 may be used to move the high velocity fluid jet or jets formed at assembly 12 or 32 across the face of the stencil 40 as the stencil and fabric are rotated together on roll 20. If a sufficiently wide multiple jet array is used, traversing means 14 is unnecessary. The fluid streams directly contact the fabric only where permitted by apertures in the stencil 40.
  • the stencil is configured to allow the fabric to be patterned to be in the form of a moving web.
  • Figures 9 and 10 show a configuration whereby a cylindrical stencil 40A is arranged to accommodate a multiple jet array orifice assemly such as shown at 32 within the stencil 40A.
  • orifice assembly 32 preferably comprises an array of jets which extends across the entire width of stencil 40A, which in turn extends across the entire width of fabric web 26.
  • Orifice assembly 32 is preferably located in close proximity to the inside surface of cylindrical stencil 40A; the outer surface of stencil 40A is preferably located in close proximity to, and perhaps in direct contact with, the surface of fabric web 26.
  • Means, not shown, are provided to achieve smooth rotation of stencil 40A in synchronism with the movement of fabric web 26. This may be achieved, for example, by an appropriate gear train operating on a ring gear which is associated with one or both ends of cylindrical stencil 40A.
  • a single or multiple jet array may be used which is made to traverse within cylindrical stencil 40A so that the entire width of fabric web 26 may be treated.
  • Use of such traversing jet or jet array would preferably require incremental movement of fabric web 26, as discussed above.
  • By inducing small, reciprocating lateral motions to the jet or jets i.e., shogging"
  • more complete or even area coverage on the fabric may be achieved for a given jet size.
  • FIGS 11 through 13 depict various views of an apparatus which may be used to interrupt a thin, high velocity stream of fluid, e.g., water, in accordance with electrically coded command information.
  • Conduit 10A supplies, via a suitable threaded connector, the water or other liquid at the desired pressure and flow rate to generally "U"-shaped orifice block 50.
  • Within block 50 is threaded input cavity 52, at the end of which is drilled bore 54 which connects cavity 52 with the opposite face of block 50.
  • Bore 54 is dimensioned and shaped in accordance with the desired stream cross section of the fluid to be controlled.
  • Reed assembly 58 Associated with orifice block 52 is spring-like reed assembly 58, comprised of a thin, flat section of flexible material such as metal shim stock, as depicted in Figure 13, secured at each end of the base portion of assembly 58 by bolts 56, only one of which is shown.
  • Reed assembly 58 has a flat, proximal portion attached securely to the inside face of block 52 which carries bore 54, and an aperture 59 through which the fluid jet from bore 54 may pass without obstruction.
  • Reed assembly 58 also has a flat, cantilevered portion which extends directly over and parallel to, and is aligned with, the path of the liquid stream formed by bore 54.
  • Reed assembly 58 is positioned within orifice block 50 so as to permit the free or distal end of the cantilevered portion of reed assembly 58 to be urged into the path of the high velocity liquid stream emerging from bore 54, as by the action of plunger 60.
  • a liquid jet of relatively high velocity strikes the protruding free end portion of reed assembly 58, the jet does not appear to be deflected or diverted as a coherent stream, but instead appears to be completely disrupted-a dense mist is produced, and little semblance of a column of liquid remains.
  • plunger 60 is withdrawn the impact of the liquid on the free end of reed assembly 58 serves to restore it to its original position above the path of the liquid jet, with an extremly fast response time.
  • Plunger 60 may be actuated by an electrically controlled solenoid 62 of the type used in impact printers, which may be actuated in accordance with electrically supplied pattern information.
  • solenoid 62 of the type used in impact printers
  • a pneumatic valve and air cylinder associated with a means for controlling air pressure in response to pattern information, may be substituted for the solenoid.
  • Set screw 63 is used to firmly position solenoid 62 within orifice block 50.
  • aperture plate 64 Directly opposite bore 54 is aperture plate 64, through which is drilled a hole 65 slightly larger than the cross sectional dimensions of the liquid jet at that point in the jet's trajectory.
  • Aperture plate 64 secured to orifice block 50 by means of bolts 55, serves to form a containment barrier for the remnants of the jet resulting from the intrusion of the free end of reed assembly 58 into the path of the jet.
  • drain channels or other means to carry off the jet liquid may be provided by any convenient means.
  • Figures 14 through 17 depict several embodiments of this apparatus wherein multiple jets may be formed and controlled by use of a plunger- activated reed which is urged into the jet path.
  • two separate arrays of reeds 81, 82 similar to that depicted in Figure 15 are mounted in generally opposed relation in control blocks 79, 80, forward of and on either side of a linear array of stream- forming bores or orifices 75 which are drilled or otherwise formed in orifice block 74.
  • the flat, cantilevered portions of reed arrays 81, 82 are aligned with the respective streams formed by bores 75.
  • Orifice block 74 is attached by conventional means, for example, by bolts 73, to liquid distribution manifold 70 which in turn is connected, via threaded inlet 72 and filter assembly 71, to a high pressure source of the desired working fluid, not shown.
  • Upper and lower barrier plates 88, 89 are mounted in front of reed arrays 81,82; a slot-like cut-out in plates 88, 89, shown in Figure 17, permits the liquid jets to strike fabric 25, roll 21, or other target, whenever the individual reeds in arrays 81, 82 are not engaging the respective jets formed by bores 75.
  • extension of plunger 84 causes respective reed 81 to intrude into the path of the liquid jet issuing from respective bore 75, thereby disrupting the jet and causing whatever remains of the jet to strike barrier plate 89.
  • reed arrays 81, 82 As depicted in Figure 17, which is a section view taken along lines XVII-XVII of Figure 15, reed arrays 81, 82, as well as the individually command-actuated plungers 84which are individually associated and aligned with each reed in arrays 81, 82, are positioned in staggered or alternating relationship on either side of the array of orifices 75.
  • Such arrangement allows for the interleaving of individual reeds in arrays 81, 82 from opposite sides of control blocks 79, 80 where two or more adjacent jets are to be nullified.
  • Plungers 84 may be activated in a conventional manner by electromagnetic means, pneumatic means, etc., such as the solenoid disclosed above and shown at 86; preferably, plungers 84 are responsive to digitally encoded data supplied by an EPROM or similar source.
  • Figures 18 and 19 depict a variation of the apparatus shown in Figures 14, 16, and 17 which relates primarily to the manner in which the jet- forming bores or orifices are formed.
  • Slot block 90 having a "U"-shaped cross-section, is used to form a fluid manifold 91 in conjunction with containment block 94.
  • Within the broad upper face of block 90 nearest to reed arrays 81, 82 are cut a series of uniformly spaced parallel slots or grooves 92 having a depth, width, and profile corresponding to the cross-section of the desired liquid jets.
  • Grooves 92 allow pressurized fluid to exit manifold 91 and strike roll 21, unless the fluid stream is otherwise interrupted by the action of reed arrays 81, 82.
  • a flat containment block 94 is securely pressed against the top of block 90 by means of bolts 95 which extend through support block 98, forming a pressure-resistant, fluid tight seal.
  • High pressure fluid such as water, supplied via filter 71, is introduced into the manifold formed by blocks 90, 94 by way of a suitable conventional threaded coupling.
  • Bolts 96 which may extend through support block 98, serve to align and secure blocks 90 and 94 against control blocks 79, 80, which collectively house arrays of reeds 81, 82, plungers 84, valves 86, and barrier plates 88 and 89, as in the embodiment of Figures 14 through 17 and as shown in Figure 19.
  • Control blocks 79, 80 may be secured to support block 98 by means of bolts 99 or other suitable means.
  • Figures 20 and 21 depict various views of another apparatus which may be used to interrupt the impact of a thin, high velocity stream of fluid in accordance with externally supplied command information such as digitized electrical signals.
  • the thin stream of fluid is formed by passing the fluid through a stiff, cantilevered thin walled tube which is mechanically deflected by means of a piston or other means acting near the cantilevered end of the tube to direct the fluid against a barrier rather than against the fabric surface.
  • a conduit supplies the desired fluid (the "working" fluid) at the desired pressure and flow rate, via a suitable connector, to cavity block 110.
  • desired fluid the "working” fluid
  • cavity block 110 Within block 110 is input manifold or cavity 112.
  • a passage 114 is drilled or otherwise placed in the side of block 110; this passage is sized to accommodate a stiff, thin walled tube 116 which has a bore size and shape corresponding to the size and shape of the desired fluid stream to be produced.
  • block 110 may be made in the form of two mating halves, so that the passage 114 may be formed by machining a groove in the face of one or both halves rather than by drilling a hole.
  • Tube 116 which may be made of stainless steel or other suitable material, is inserted into passage 114 and securely affixed therein to assure that the high pressures associated with the working fluid will not dislodge the tube or cause leakage of the working fluid.
  • Tube 116 is made to protrude from passage 114 in the direction of roll 21 a sufficient distance to permit the deflection of the free or distal end portion of tube 116 through a small angle without damage to tube 116.
  • plunger 120 Closely associated with tube 116 is plunger 120, which is positioned near the cantilevered or distal end of tube 116 so as to cause a deflection of tube 116 whenever plunger 120 is extended.
  • Barrier plate 118 is securely affixed slightly forward of the distal end of tube 116, and extends toward the path of the fluid stream far enough that the fluid jet formed by tube 116 strikes the upper portion of plate 118 whenever tube 116 is deflected by plunger 120, as shown in Figure 21. Whenever tube 116 is not deflected, the resulting jet passes over the upper portion of barrier plate 118, as depicted in Figure 20. If desired, the configuration of barrier plate 118 may be inverted so that the jet passes over the edge of barrier plate 118 only when tube 116 is deflected. Associated with barrier plate 118 are drains, not shown, for carrying the deflected liquid away for disposal or recycling.
  • Plunger 120 may be actuated in a conventional manner by an electrical solenoid, an air cylinder and pneumatic valve, or other means, depicted at 122.
  • the end of plunger 120 which makes contact with tube 116 may be formed to accommodate the contour of tube 116, i.e., may be formed to surround or grip, partially or completely, tube 116; it is preferred that, regardless of the contour of the end portion of plunger 120, the stroke of plunger 120 be adjusted so that plunger 120, when not deflecting tube 116, extends to a point closely adjacent to or in contact with tube 116, so that when plunger 120 is extended to deflect tube 116, little motion will be lost and unwanted oscillations will be minimized.
  • Figures 22 through 28 depict an apparatus related in operation to the apparatus of Figures 20 and 21, but suitable for controlling an array of jets formed in the manner depicted in Figures 20 and 21.
  • the working fluid is introduced into a generally cylindrical input cavity 132 formed along the length of orifice block 130, via high pressure conduit 10A ( Figure 24) and a suitable threaded connector.
  • Tubes 136 each having the desired inside dimensions and positioned generally perpendicularly to the surface of roll 21, are securely affixed to passages 134 in orifice block 130 which conform to the outside dimensions of tubes 136.
  • the fluid contained at high pressure within cavity 132 may be directed through tubes 136 in the direction of the surface of fabric 25, roll 21, or other target.
  • tubes 136 extend through passages 134 to cavity 132.
  • Tubes 136 may be secured within passages 134 by soldering the tubes directly to orifice block 130 by soldering a collar to the tube which fits snugly within a mechanical recess in block 130, or by other suitable means.
  • Tubes 136 should be of such design, and should extend far enough from orifice block 130, so that deflections of tubes 136 through small angles by the action of plungers 140 will not cause undesirable deformation of tubes 136.
  • plunger guides 141 Securely positioned a short distance from orifice block 130 is deflection frame 138, through which are fed flexible deflecting plungers 140 sheathed by hollow plunger guides 141.
  • Plungers 140 may be constructed of stainless steel or other suitable material; plunger guides 141 may be tubes of appropriate bore size, made of any suitable material having the necessary flexibility to allow for desired bending and shaping.
  • Each plunger 140 and plunger guide 141 is associated with a respective individual tube 116 and is precisely aligned by deflection frame 138. Each plunger 140 is adjusted to make contact with its respective tube 136 even when that tube is in its undeflected position, as shown in Figures 23 and 25.
  • Deflection frame 138 may also serve as a guide to align the movement of tubes 136 during deflection and recovery, as suggested in Figure 23.
  • Plungers 140 are actuated by valves 142 which, because of their relative bulk, are situated somewhat remotely from the point at which plungers 140 act on tubes 136.
  • deflection frame 138 may be made to accommodate eight separate valve/plunger assemblies, and, together with a section of orifice block 130 containing eight tubes 136, may form a fluid control module which may be juxtaposed, as in Figure 24, to allow simultaneous treatment over a relatively wide roll surface.
  • Figures 27 and 28 depict an apparatus similar to that disclosed immediately above, for use where increased jet density (i.e., number of jets per linear distance across the face of roll 21) is desired. In this configuration, twice the jet density of the apparatus of Figures 22 through 24 may be achieved. In this configuration, two parallel arrays of tubes 136, 136A, are inserted into orifice block 130A via passages 134, 134A and communicate with chamber or manifold 132A.
  • the deflection frame 138, array of plungers 140, plunger guides 141, arrangement of valves 142, and placement of barrier lip 144 of Figure 22 have been substantially duplicated at 138A, 140A, 141A, 142A and 144A, respectively, to achieve an "over/ under" apparatus which, in Figure 27, appears to be an almost mirror-image combination of the apparatus configuration of Figure 22.
  • the opposing tube arrays 136, 136A and deflection frames 138,138A are offset, as shown in Figure 28, to permit uniform positioning of the additional jets in the direction of the axis of roll 21.
  • the tubes 136, 136A from the upper and lower arrays of Figure 28 will not form a straight line along the axis of roll 21.
  • This staggered alignment is intended to compensate for the non-normal orientation of the tubes 136, 136A to the surface of roll 21 in their deflected position.
  • the small angle induced by the action of plungers 140, 140A will cause, upon proper adjustment of the overall distance to the surface of roll 21, the plunger extension length, etc., the jets emitted by the staggered tubes 136, 136A to strike the surface of roll 21, or a substrate 25 placed against the roll, in substantially perfect alignment.
  • Figures 29 through 32 depict yet another apparatus which may be used for the purpose of forming and interrupting the flow of a high pressure fluid stream, such as is used in the principal invention disclosed herein.
  • a conduit 10A supplies, via filter 71 ( Figure 29), a high pressure fluid to manifold cavity 162 formed within inlet manifold block 160.
  • Flange 164 is formed along one side of manifold block 160; into the base of flange 164 is cut a uniformly spaced series of parallel grooves 166. Each groove 166 extends from cavity 162 to the forwardmost edge of flange 164 and has cross-sectional dimensions corresponding to the desired cross-sectional dimensions of the stream.
  • Control tubes 170 through which streams of relatively low pressure air or other control fluid are passed on command, are arranged in one-to-one relationship with grooves 166, and are, in one embodiment, positioned substantially in alignment with and perpendicular to grooves 166 by means of a series of sockets or wells 172 in flange 164, each of which are placed in direct vertical alignment with a respective groove 166 in flange 164, and into which each tube 170 is securely fastened.
  • the floor of each socket 172 has a series of small passages 174 which in turn communicate directly with the base of its respective groove 166.
  • One configuration for passages 174 is a series of aligned circular apertures, as shown in Figure 32.
  • grooves 166 may be made wider and more shallow, and a single, larger passage may be substituted for small passages 174.
  • the arrangement of the tube/ socket combinations optionally may be staggered so that grooves 166 may be more closely spaced without adversely effecting the structural integrity of flange 164.
  • outlet manifold block 180 and containment plate 178 Positioned opposite inlet manifold block 160 and securely abutted thereto via bolts 161 are outlet manifold block 180 and containment plate 178. Containment plate 178 may be attached to outlet manifold block 180 by means of screws 179 or other suitable means.
  • a discharge cavity 182 and outlet drain 184 Within outlet manifold block 180 is machined a discharge cavity 182 and outlet drain 184.
  • Discharge cavity 182 and outlet drain 184 may extend across several grooves 166 in flange 164, or individual cavities and outlets for each groove 166 may be provided. It is preferred, however, that cavity 182 be positioned so that passages 174 lead directly into cavity 182, and not lead into the upper surface of outlet manifold block 180 or containment plate 178.
  • Discharge cavity 182 includes impact cavity 177 which is machined into containment plate 178.
  • Bolts 183 and 185 provide adjustment of the relative alignment between inlet manifold block 160 and the combination of outlet manif
  • a high pressure working fluid is fed into inlet cavity 162, where it is forced to flow through a first enclosed passage, formed by grooves 166 in flange 164 and the face of outlet manifold block 180 opposite flange 164, thereby forming the fluid into discrete streams having a desired cross-sectional shape and area.
  • the pre-formed streams then traverse the width of discharge cavity 182, while being guided only by the grooves 166 in flange 164.
  • the streams of working fluid may be made to traverse the width of discharge cavity 182 in an open channel formed only by grooves 166 without a significant loss in the coherency or change in the cross-sectional shape or size of the stream.
  • the streams After traversing the width of discharge cavity 182, the streams encounter the edge of containment plate 178, whereupon the streams are made to flow in a second completely enclosed passage, formed by grooves 166 in flange 164 and the upper end of containment plate 178, just prior to being ejected in the direction of roll 21.
  • control fluid Even though at a vastly lower pressure than the dynamic pressure of the working fluid (i.e., one twentieth or less), is able to lift the working fluid stream from the groove 166 and cause instabilities in the stream which lead to virtual disintegration of the stream.
  • Figure 31 indicates the liquid stream is merely deflected into the curved impact cavity 177 of containment plate 178, in fact the liquid stream appears to be almost completely distintegrated by the intrusion of a relatively low pressure control fluid stream as soon as the liquid stream is free of the walls of groove 166; it is believed impact cavity 177 and containment plate 178 serve principally to contain the energetic mist which results from such disintegration.
  • the streams of high velocity liquid employed in this invention have been used to pattern or texturize a variety of commercially available textile fabric substrates. Depending upon the nature of the substrate and the operating conditions chosen, many visually distinctive patterning and texturizing effects are possible using the teachings herein, as may be determined from the following illustrative examples, which are not intended to be limiting in any way.
  • Source of pattern data EPROM, with appropriate associated electronics of conventional design.
  • Fluid jet control The apparatus depicted in Figures 20 and 21, using an electrical solenoid to activate plunger 120.
  • Roll Solid, smooth aluminum, rotating at a circumferential speed of 10 yards/minute in same direction as warp yarns in fabric.
  • the fabric sample was secured, face side outward, to the carrier roll, which was rotated continuously at the specified speed.
  • the jet nozzle was automatically traversed along the axis of the roll at a rate corresponding to the specified pattern gauge, using an apparatus arrangement similar to that shown in Figure 1. Impingement of the water jet with the fabric surface was interrupted by the action of the solenoid deflecting the stiff tube which formed the water stream in response to data being furnished by the EPROM. This procedure produced a visually similar pattern or effect on both sides of the fabric, as may be seen in the photomicrographs of Figures 33 through 36. Both the fill yarns and the warp yarns were displaced. Certain yarns, especially the fill yarns, were raised giving the fabric face a three-dimensional effect.
  • Source of pattern data Stencil carrying pattern outline.
  • Fluid jet control Stencil carrying pattern outline.
  • Roll Solid, smooth aluminum, rotating at a circumferential speed of 10 yards per minute.
  • the fabric sample was secured to the carrier roll, face side outward, and was then covered with a cylindrical stencil carrying the outline of the desired pattern.
  • the carrier roll was rotated continuously at the specified speed.
  • the jet nozzle was automatically traversed along the axis of the roll at a rate corresponding to the specified gauge. Impingement of the jet with the fabric surface (face side) was interrupted by the interposition of the plastic stencil between the nozzle and the fabric surface. This procedure produced a visually discernible effect on both sides of the fabric, as may be seen from the photomicrographs of Figures 37 and 38.
  • the treatment reduced the pile height by bending the free ends over and downward towards the base or substrate. There is a distinct two-level sculpturing effect, as well as a distinct difference in reflectivity between the treated and untreated areas. No significant penetration of pile yarns into or through the substrate was observed on the back of the treated fabric.
  • the water jet was directed toward the face of the fabric, i.e., toward the fabric pile.
  • the pile was inverted, i.e., the free pile ends were driven through the backing material and protruded through the back of the fabric.
  • the ground yarns were clearly visible. The effect can be clearly seen from the photomicrographs of Figures 39 through 42.
  • Pattern gauge 16 lines per inch.
  • the water stream was directed to the back of the fabric.
  • the rotation of the roll corresponded to the fill direction.
  • the effects of the patterning may be seen from an inspection of the photomicrographs of Figures 48 through 51.
  • a Jacquard-like patterning effect was produced.
  • the chief effect was a raising and spreading of the float yarns and fibers.
  • the water stream was directed to the face of the fabric.
  • the roll direction corresponded to the warp direction.
  • the resulting patterned fabric may be seen in the photomicrographs of Figures 52 through 54.
  • On the face of the fabric there was a severe displacement of warp yarns, almost resembling a lace-like effect. Only minor spreading of fill yarns was observed, but fill yarn bundles were opened somewhat, i.e., they were made somewhat more bulky. The warp yarns were raised.
  • the displacement of the long float yarns tended to reduce the reflectance of the fabric.
  • On the back of the fabric a somewhat similar effect was observed; however, the absence of long float yarns significantly attenuated the effect.
  • Example 7 The procedures of Example 7 were followed, except that the fabric of Example 7 was arranged so that the roll direction corresponded to the fill direction.
  • the resulting patterned fabric may be seen in the photomicrographs of Figures 55 and 56. As may be seen, there was displacement of the fill yarns especially of the float yarns which were displaced somewhat further vertically than lat - erally. There was also a compaction of the weave and yarn structure surrounding the areas where the fill yarns were displaced. The warp yarns were opened to a significant degree. On the back of the fabric, a somewhat similar, but attenuated, effect was observed.
  • the water stream was directed to the face of the fabric.
  • the direction of roll rotation corresponded to the fabric warp direction.
  • the water stream was directed at the face of the flocked fabric.
  • a significant portion of the short pile was lost, while another significant portion of the pile yarns were laid down, and yet other portions of the pile yarns were bent over and driven through the substrate to the back.
  • the substrate as viewed from the back of the fabric, exhibited an opening and compaction of constituent yarns as well as expansion and compaction of the weave structure.
  • fibers which were initially substantially parallel prior to treatment were substantially disoriented following treatment, and the substrate fabric was exposed in many places. It is observed that the amount of substrate exposed is related to the velocity of the water jet used in the treatment. See Figures 59 through 61.
  • the water stream was directed to the face of the fabric, with the roll direction corresponding to the warp direction.
  • the back of the fabric was treated in a similar manner in a subsequent step.
  • the stream diameter was 0.008 inch; the nozzle was placed approximately one-eighth inch away from the fabric surface.
  • the resulting patterned fabric may be seen in the photomicrographs of Figures 62 through 65. As may be seen, the warp yarns were separated and somewhat displaced and skewed. A similar effect was observed on the back of the fabric.
  • the treatment resulted in both a reflected light and transmitted light effect (see Figures 63 and 64).
  • Example 11 The fabric of Example 11 is processed as in Example 11, except that the orifice diameter is 0.017 inch.
  • the resulting pattern fabric may be seen in the photomicrographs of Figures 66 through 69. There was a breaking up of the uniform arrangement of light and dark yarns by yarn displacement. It is observed generally that where a fabric exhibits a relatively tightly woven warp, the fluid stream tends to displace the fill yarns, and vice versa. It should be noted that the reflected and transmitted light photomicrographs (i.e., Figures 67 and 68) indicate that there was both a reflected light and transmitted light effect. Such effect, while discernible in the fabric of Example 11, was significantly more dramatic in this Example.
  • Pattern gauge Approximately 16 lines per inch.
  • the water stream was directed to the face of the fabric.
  • the resulting pattern fabric may be seen in the photomicrographs of Figures 77 through 80.
  • a multi-level effect has been introduced in the wales in the form of generally "U"-shaped grooves which form corresponding ridges on the opposite side of the fabric.
  • Figures 78 and 79 show a compaction of the knit structure in the region of the grooves. Yarn bulking and spreading in the treated area of observed. There is a significant degree of fiber raising on the back of the fabric. (See Figure 80).
  • Pattern gauge Five parallel “lines” or jet tracks, spaced approximately 0.067 inch apart and arranged in groups which are spaced approximately 0.37 inch apart.
  • Nozzle Diameter 0.012 inch.
  • Fluid Water, at a pressure of 2000 p.s.i.g.
  • the water stream was directed onto the face of the fabric from an array comprised of five separate nozzles.
  • the resulting fabric is shown in the photomicrographs of Figures 81 through 84.
  • there is a compaction of the weave structure in both the warp and the fill direction which results in buckling or puckering of the untreated fabric between adjacent groups of jet tracks.
  • This buckling or puckering may be removed by drying the wet fabric under moderate tension.
  • the water stream was directed onto the face of the fabric.
  • the resulting fabric is shown in the photomicrographs of Figures 85 through 87. As may be seen, there is a raising of the yarns at corresponding locations on both the face and the back of the fabric, resulting in the formation of ridges on exactly opposite sides of the fabric which produce a slub-like appearance. There is an opening and a bulking of the yarn in the treated areas. Surface nap fibers are thought to be produced and displaced along the treated areas. Most of such produced nap fibers are pushed through the fabric and protrude from the fabric back surface opposite the treated areas.
  • the water pressure was maintained at 2500 p.s.i.g., the control fluid was air, which was varied in pressure from 2 to 85 p.s.i.g. in response to externally supplied pattern information.
  • the fabric was positioned approximately 0.37 inch from the forward face of flange 164. Circumferential roll speed was 5 yards per minute.
  • the resulting patterned fabric may be seen in the photomicrographs of Figures 88 through 91. As may be seen, there is a separation of adjacent warp yarns, as well as some bulking of the treated yarns. Surface nap fibers are thought to be produced and displaced along the treated areas. Most of such produced nap fibers are pushed through the fabric and protrude from the fabric back surface opposite the treated areas.
  • the reed was fashioned out of stainless steel shim stock having a thickness of 0.003 inch. Deflection was via a deflector plate located approximately 0.5 inch from the exit of the water jet. The deflector plate was provided with a hole approximately 0.05 inch in diameter to allow the undeflected jet to pass therethrough and strike the fabric. Actuation of the reed was provided by a miniature air cylinder distributed by Tomita Company, Limited, of Tokyo, Japan as Model Number 1C-0.10-NFS-0.197. The air cylinder plunger was spaced approximately 0.03 inch from the reed. The air cylinder was in turn controlled by an air valve distributed by the Lee Company, of Westbrook, Connecticut as Model Number LFAX0460900AG.
  • Air pressure was maintained at 60 p.s.i.g.
  • a high velocity stream of water was projected onto the textile fabric substrate in accordance with pattern data supplied by an EPROM and associated electronics.
  • the fabric was spaced about 0.75 inch from the exit point of the water jet; the circumferential speed of the roll to which the fabric was attached was approximately four inches per second.
  • the resulting pattern fabric may be seen in the photomicrographs of Figures 92 through 94. There was a breaking up of the uniform arrangement of light and dark yarns by yarn displacement, with both a reflected light and transmitted light effect. Upon close inspection, the fabric effect appeared to be generally similar to that achieved in Example 12, and shown in Figures 66 through 69.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Nonwoven Fabrics (AREA)
EP85306852A 1984-09-28 1985-09-26 Method and apparatus for patterning substrates Expired - Lifetime EP0177277B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT85306852T ATE58563T1 (de) 1984-09-28 1985-09-26 Verfahren und vorrichtung zum herstellen von mustern auf ein substrat.

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US65596884A 1984-09-28 1984-09-28
US65596684A 1984-09-28 1984-09-28
US65596784A 1984-09-28 1984-09-28
US65611984A 1984-09-28 1984-09-28
US655968 1984-09-28
US655967 1984-09-28
US655966 1984-09-28
US656119 1984-09-28

Publications (2)

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EP0177277A1 EP0177277A1 (en) 1986-04-09
EP0177277B1 true EP0177277B1 (en) 1990-11-22

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EP (1) EP0177277B1 (fi)
JP (1) JP2609223B2 (fi)
KR (1) KR920006469B1 (fi)
AU (1) AU581024B2 (fi)
DE (1) DE3580643D1 (fi)
DK (1) DK438685A (fi)
ES (4) ES8701872A1 (fi)
FI (1) FI87807C (fi)
IE (1) IE56947B1 (fi)
IL (1) IL76495A (fi)
MX (1) MX162576A (fi)
NZ (1) NZ213654A (fi)
PT (1) PT81218B (fi)
TR (1) TR22563A (fi)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0228197A1 (en) * 1985-12-05 1987-07-08 Toray Industries, Inc. Napped sheet having a pattern thereon and method for its production
WO1989010441A1 (en) * 1988-04-21 1989-11-02 Veratec Inc. Apparatus and method for hydroenhancing fabric
US4953270A (en) * 1987-09-04 1990-09-04 Milliken Research Corporation Method for marking textile substrates
US4967456A (en) * 1987-04-23 1990-11-06 International Paper Company Apparatus and method for hydroenhancing fabric
US4995151A (en) * 1988-04-14 1991-02-26 International Paper Company Apparatus and method for hydropatterning fabric
US5136761A (en) * 1987-04-23 1992-08-11 International Paper Company Apparatus and method for hydroenhancing fabric
US5337460A (en) * 1993-01-21 1994-08-16 Milliken Research Corporation Method and apparatus to create an improved moire fabric
US5405684A (en) * 1993-01-21 1995-04-11 Milliken Research Corporation Moire fabric
WO1995021740A1 (en) * 1993-01-21 1995-08-17 Milliken Research Corporation Method and apparatus to create an improved moire fabric
US5632072A (en) 1988-04-14 1997-05-27 International Paper Company Method for hydropatterning napped fabric
US5657520A (en) * 1995-01-26 1997-08-19 International Paper Company Method for tentering hydroenhanced fabric
US5737813A (en) 1988-04-14 1998-04-14 International Paper Company Method and apparatus for striped patterning of dyed fabric by hydrojet treatment
US5806155A (en) 1995-06-07 1998-09-15 International Paper Company Apparatus and method for hydraulic finishing of continuous filament fabrics
EP1310226A2 (de) 2001-11-08 2003-05-14 W. Pelz GmbH & Co. Kosmetisches Wattepad

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61252339A (ja) * 1985-04-30 1986-11-10 東レ株式会社 織編物およびその製造方法
DE10064687A1 (de) * 2000-12-22 2002-07-04 Fleissner Maschf Gmbh Co Verfahren zur hydrodynamischen Beaufschlagung einer auch mit endlichen Produkten versehenen Warenbahn mit Wasserstrahlen und Düseneinrichtung zur Erzeugung von Flüssigkeitsstrahlen
DE10132563A1 (de) * 2001-07-10 2003-01-30 Fleissner Maschf Gmbh Co Verfahren zur farblosen Musterung einer Warenbahn und Vorrichtung zur Durchführung des Verfahrens
EP2302120B1 (de) * 2009-09-22 2012-06-20 Groz-Beckert KG Injektor für eine Textilbearbeitungsmaschine
CN112088230B (zh) 2018-05-25 2023-10-27 宝洁公司 非织造布及其生产方法和设备
WO2019222991A1 (en) * 2018-05-25 2019-11-28 The Procter & Gamble Company Process for producing nonwoven and apparatus suitable therefor

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US3508308A (en) * 1962-07-06 1970-04-28 Du Pont Jet-treatment process for producing nonpatterned and line-entangled nonwoven fabrics

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US3635625A (en) * 1970-01-12 1972-01-18 Phillips Petroleum Co Apparatus for carving a material sheet
US4095444A (en) * 1977-06-15 1978-06-20 Milliken Research Corporation Apparatus for the application of liquids to moving materials
JPS6055627B2 (ja) * 1978-04-13 1985-12-05 帝人株式会社 立毛布帛に天然皮革様外観を付与するための装置
US4418451A (en) * 1981-01-23 1983-12-06 Milliken Research Corporation Methods for the production of multi-level surface patterned materials
US4393562A (en) * 1981-01-23 1983-07-19 Milliken Research Corporation Apparatus for imparting visual surface effects to relatively moving materials
US4471514A (en) * 1981-07-10 1984-09-18 Milliken Research Corporation Apparatus for imparting visual surface effects to relatively moving materials
DK268683A (da) * 1982-06-11 1983-12-12 Milliken Res Corp Fremgangsmaade og apparat til frembringelse af visuelle overfladeeffekter

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US3508308A (en) * 1962-07-06 1970-04-28 Du Pont Jet-treatment process for producing nonpatterned and line-entangled nonwoven fabrics

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0228197A1 (en) * 1985-12-05 1987-07-08 Toray Industries, Inc. Napped sheet having a pattern thereon and method for its production
US4967456A (en) * 1987-04-23 1990-11-06 International Paper Company Apparatus and method for hydroenhancing fabric
US5136761A (en) * 1987-04-23 1992-08-11 International Paper Company Apparatus and method for hydroenhancing fabric
US4953270A (en) * 1987-09-04 1990-09-04 Milliken Research Corporation Method for marking textile substrates
US5632072A (en) 1988-04-14 1997-05-27 International Paper Company Method for hydropatterning napped fabric
US4995151A (en) * 1988-04-14 1991-02-26 International Paper Company Apparatus and method for hydropatterning fabric
US5737813A (en) 1988-04-14 1998-04-14 International Paper Company Method and apparatus for striped patterning of dyed fabric by hydrojet treatment
WO1989010441A1 (en) * 1988-04-21 1989-11-02 Veratec Inc. Apparatus and method for hydroenhancing fabric
US5337460A (en) * 1993-01-21 1994-08-16 Milliken Research Corporation Method and apparatus to create an improved moire fabric
US5475905A (en) * 1993-01-21 1995-12-19 Milliken Research Corporation Apparatus to create an improved moire fabric
WO1995021740A1 (en) * 1993-01-21 1995-08-17 Milliken Research Corporation Method and apparatus to create an improved moire fabric
US5405684A (en) * 1993-01-21 1995-04-11 Milliken Research Corporation Moire fabric
US5657520A (en) * 1995-01-26 1997-08-19 International Paper Company Method for tentering hydroenhanced fabric
US5806155A (en) 1995-06-07 1998-09-15 International Paper Company Apparatus and method for hydraulic finishing of continuous filament fabrics
EP1310226A2 (de) 2001-11-08 2003-05-14 W. Pelz GmbH & Co. Kosmetisches Wattepad

Also Published As

Publication number Publication date
JPS61179361A (ja) 1986-08-12
ES547381A0 (es) 1986-12-01
ES8706873A1 (es) 1987-07-01
ES555191A0 (es) 1987-07-01
IL76495A0 (en) 1986-01-31
JP2609223B2 (ja) 1997-05-14
ES555192A0 (es) 1987-02-16
FI853707L (fi) 1986-03-29
IE852369L (en) 1986-03-28
FI87807C (fi) 1993-02-25
NZ213654A (en) 1990-08-28
DK438685A (da) 1986-03-29
IE56947B1 (en) 1992-02-12
ES555193A0 (es) 1987-08-16
ES8703551A1 (es) 1987-02-16
MX162576A (es) 1991-05-27
PT81218A (en) 1985-10-01
ES8707778A1 (es) 1987-08-16
EP0177277A1 (en) 1986-04-09
ES8701872A1 (es) 1986-12-01
FI87807B (fi) 1992-11-13
AU581024B2 (en) 1989-02-09
KR860002612A (ko) 1986-04-28
FI853707A0 (fi) 1985-09-26
PT81218B (pt) 1987-08-19
KR920006469B1 (ko) 1992-08-07
DE3580643D1 (de) 1991-01-03
DK438685D0 (da) 1985-09-27
IL76495A (en) 1990-09-17
TR22563A (tr) 1987-10-30
AU4794685A (en) 1986-11-27

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