EP0337777A1 - Procédé et appareil pour décorer des matières utilisant des jets de gaz - Google Patents

Procédé et appareil pour décorer des matières utilisant des jets de gaz Download PDF

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Publication number
EP0337777A1
EP0337777A1 EP89303652A EP89303652A EP0337777A1 EP 0337777 A1 EP0337777 A1 EP 0337777A1 EP 89303652 A EP89303652 A EP 89303652A EP 89303652 A EP89303652 A EP 89303652A EP 0337777 A1 EP0337777 A1 EP 0337777A1
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European Patent Office
Prior art keywords
dye
substrate
pattern
streams
gas
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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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EP89303652A
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German (de)
English (en)
Inventor
Daniel Taylor Mcbride
William Hogue Stewart, Jr.
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Milliken Research Corp
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Milliken Research Corp
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Publication of EP0337777A1 publication Critical patent/EP0337777A1/fr
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    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06CFINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00Making patterns or designs on fabrics
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06BTREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B11/00Treatment of selected parts of textile materials, e.g. partial dyeing
    • D06B11/0093Treatments carried out during or after a regular application of treating materials, in order to get differentiated effects on the textile material

Definitions

  • This invention relates to an apparatus and process for generating patterns on textile substrates carrying unfixed liquid dyes. More particularly, this invention is directed to an apparatus and process for pattern dyeing textile substrates wherein at least one stream or jet of pressurized gas is directed at the surface of a textile substrate to which has been applied, by various means, an undried and unfixed liquid dye.
  • a textile substrate which has been dyed a uniform color using an unfixed and undried liquid dye is subjected to one or more jets of air at relatively close range.
  • a textile substrate carrying an unfixed and undried liquid dye which has been applied in a pattern configuration using one or more fine sprays of dye propelled onto the substrate by a first set of gas jets, is subjected to one or more jets of air from a second set of jets at relatively close range.
  • the mechanical action of the impinging jets or streams from the second set of jets on the unfixed dye is sufficient to displace or remove, from the area of impact, dye which has not been adsorbed onto the surface of the constituent fibers, thereby removing or redistributing unfixed dye and causing the area of impact to have a significantly lower dye concentration in the area of jet impingement.
  • This area, upon fixing of the dye is therefore dyed a visually lighter or less saturated shade of the dye than the surrounding non-impacted area.
  • liquid dye shall be used to mean dyes, inks, or the like comprised of soluble matter in a solvent, as well as dyes or marking materials comprised of insoluble matter in a liquid medium.
  • substrate is intended to encompass a wide range of textile constructions, such as woven or knitted fabrics, and may include non-woven constructions. Both flat and pile-like fabrics have been successfully patterned using the teachings herein, and are intended to be included in the term textile substrate as well. Fabrics comprised of various synthetic yarn types may be used including, but not limited to, polyester, nylon, and acrylic yarns.
  • any yarn type or fabric construction which allows some unfixed liquid dye to be redistributed or removed by the action of an impinging gas stream may be patterned using the teachings herein.
  • the term "momentum flux" is used to describe the relative concentration of momentum of the air stream (i.e., the product of air mass and air velocity) striking the substrate. By using momentum flux as a parameter, various other process variables such as gas pressure, gas stream velocity at impact, and gas stream cross-sectional area may be implicitly accommodated.
  • the streams may be either continuously flowing onto the substrate surface, or may be intermittently initiated or interrupted in a variety of ways in accordance with pattern data. This method, which may afford some flexibility in pattern configuration, often requires a complex arrangement of valves and dye discharge devices which are costly and may require careful or continuing adjustment.
  • a characteristic of either technique is the limitation of shade flexibility generally afforded by such techniques due to the practical need to use a separate dye mix for each desired shade, and the limited number of dye mixes usually available for each substrate pass.
  • resist printing Another printing technique is resist printing, wherein a resist chemical is first applied to a dyed or undyed substrate in a specified area.
  • the resist chemical can contain a dye or pigment.
  • the substrate surface may be applied with a dye which, due to the blocking effect of the resist, does not affect the areas under the resist. Because of the multiple steps required, this process is more costly than applying a single batch of dye directly to the substrate.
  • the control of color intensity or shading must be accomplished through the use of carefully formulated resist chemicals. Generally, it is difficult to achieve even moderately fine gradations of shading with this technique.
  • Discharge printing is yet another printing technique wherein a previously dyed or undyed substrate is dyed overall with a background shade, after which a chemical agent is applied to the substrate to discharge or chemically reduce the color of the background shade and eliminate, at least partially, the background shade from that area of the substrate.
  • the background dye mix can contain dyes resistant to reduction by the discharge agent. In areas containing such dyes, the background color will remain.
  • the discharge mix can itself contain dyes which are intended to replace or re-dye areas from which the original background dye has been chemically reduced. This technique requires highly specialized and expensive dyes, and is difficult to control if fine or uniform shade gradations are to be reproduced dependably.
  • the invention disclosed herein provides a method for dyeing a textile substrate with a variety of shade variations of a given background (which may be comprised of one or more colors arranged in a diffuse pattern), without the uncertainty associated with resist or discharge printing techniques, and without the inflexibility or complexity associated with certain direct printing techniques.
  • the invention provides a method in which a variety of shade variations may be reproducibly generated on a moving textile substrate by removing or redistributing, in a controlled, selective manner, unfixed and undried liquid dye from the substrate to produce various color shades and patterns.
  • the manner in which the dye is placed initially on the substrate depends upon the nature of the final pattern desired.
  • the unfixed liquid dye is applied uniformly over the fabric to be patterned, and is then removed or redistributed in its unfixed state by the impingement of one or more jets of air to form a pattern. This results in a pattern limited to the various shades of the applied color, in combination with the initial color of the substrate.
  • the unfixed liquid dye is applied in a pattern configuration, using one or more streams or jets of gas (e.g., air) to generate a fine spray of liquid dye droplets and, at the same time, direct such spray onto selected areas of the substrate surface.
  • gas e.g., air
  • the unfixed liquid dye is then further patterned by selective redistribution or removal of the dye by the impingement of an independent set of gas jets (e.g., air) in accordance with the teachings herein to produce a novel effect.
  • gas jets e.g., air
  • This embodiment uses jets of gas to apply dye in a pattern and then uses different jets of gas to rearrange or remove, in a similar or a different pattern, some of the dye so applied.
  • unfixed and undried liquid dye on a substrate surface may be removed or redistributed by one or more streams or jets of pressurized gas directed at close range onto selected areas of the substrate surface.
  • air at substantially ambient temperature will be assumed to be the gas of choice, although other gases may be used as desired.
  • Removing a relatively larger amount of dye from the area will result in a more "diluted" color or tone being generated, as viewed against the fully concentrated background level of unfixed dye.
  • the resulting color may be a blend of the unfixed background dye color and the color of the substrate prior to the application of the unfixed dye. It is therefore possible to obtain multi-color effects based upon the blending of the underlying substrate color and various concentrations of the unfixed dye.
  • the application of unfixed dye in multiple colors onto a background of fixed dye (of one or more than one color) is also contemplated.
  • unfixed and undried liquid dye on a substrate surface may be applied by the use of an array of gas streams or jets which generate a spray of dye droplets in the direction of the substrate.
  • the applied dye may then be removed or redistributed by one or more independent streams or jets of pressurized gas directed at close range onto selected areas of the substrate surface.
  • patterns which are particularly visually attractive may be produced by a two stage process in which the background color of the substrate is applied in a pattern configuration using a first array of gas jets (e.g., air jets) to spray the substrate with dye droplets (Stage 1), followed by rearrangement or removal of the dye, using a second array of gas jets (e.g., air jets) (Stage 2).
  • the preferred gas for both Stage 1 and Stage 2 patterning is air at ambient temperature, although other gases may be used if desired.
  • One particular advantage of using this background generating technique is that the general diffuse character of the patterns forming the background is matched by the diffuse character of the patterning achieved by the dye rearrangement/removal technique.
  • a second particular advantage of using this background generating technique is the opportunity it presents to control both the color application and color removal processes - which are both dependent upon the control of gas jets directed at the substrate surface - with a single computer-driven process control system, making it convenient to generate patterns in register using the Stage 1 and Stage 2 processes running in tandem.
  • one or more arrays of closely spaced streams of liquid dye or ink are normally directed into a collection trough; in a preferred embodiment, a diverting surface or lip is used to intercept the streams and channel the liquid dye into the collection trough.
  • Each stream in a given array has associated with it a source of pressurized fluid, for example, air, which, on command, forms and directs an atomizing stream or jet of air on a path which brings the atomizing air stream into contact with the streams of liquid dye or ink, whereby the streams of ink or dye are transformed into a mist of variously sized droplets of ink or dye which are propelled, by the combined momentum of the liquid and air streams, in the direction of the substrate to be marked.
  • pressurized fluid for example, air
  • the continuous stream of liquid dye tends to produce some droplets which are substantially larger than the fine mist ordinarily associated with an atomization process such as is employed herein.
  • the term “microscopic fragmentation” shall be used to describe the process whereby the liquid dye is broken up into a relatively fine mist, i.e., where droplet average diameter is generally substantially smaller than about 0.1 or 0.2 millimeter.
  • the term “macroscopic fragmentation” shall be used to describe the process whereby the liquid dye is broken up into droplets having an average diameter on the order of about 0.1 or 0.2 millimeter, or larger.
  • the dye stream is atomized in the region of the stream directly in line with the advancing wave front of pressurized air, which results in microscopic fragmentation of the dye. That portion of the dye stream immediately above or below this in-line region remains coherent, but tends to become entrained in the periphery of the passing air stream and tends to separate into relatively large droplets and irregularly shaped spatters of dye (i.e., it undergoes macroscopic fragmentation) which are propelled toward the substrate.
  • the resulting color may be a blend of the unfixed background dye color and the color of the substrate prior to the application of the unfixed dye. It is therefore possible to obtain a wide variety of multi-color effects based upon the blending of the underlying substrate color and various concentrations of the unfixed dye.
  • the prompt application of a second liquid dye, as by spraying or other non-smearing means, to a substrate surface still wet from an initial application of dye results in the second color coating on the surface being relatively easy to remove using the teachings herein. It is believed that a substantial amount of the first or base layer of applied dye is adsorbed onto the fiber surfaces and becomes relatively securely attached thereto, even though unfixed. Subsequent applications of dye must look to areas of the fiber surface not yet occupied by a component of the first dye to find an adsorption site, or, finding no adsorption site, must occupy the interstitial voids between adjacent fibers or yarns. This results in the second dye having a relatively low and/or weak adsorption level, and permits substantial quantities of the second dye to be more readily removed or redistributed in accordance with the teachings described herein.
  • a special advantage of this invention is that the chosen shade variations may be modified while the substrate is being patterned - no prior preparation in the nature of formulating special dyes or other chemicals, or loading the patterning device with such dyes or chemicals, is required. Additionally, the process may be implemented using the computer controlled apparatus disclosed herein. As aided by such computer controlled apparatus, the invention may provide the following practical advantages:
  • Figures 1 and 3 and Figures 2 and 4 are alternative apparatus configurations for treating textile substrates in which the substrate is uniformly dyed and in which (1) the gas jets are intended to be reflected from the textile structure and the underlying backing member almost exclusively ( Figures 1 and 3), and (2) the gas jets are intended primarily to pass through the substrate, but with some of the gas being reflected by the yarns comprising the fabric substrate ( Figures 2 and 14).
  • textile substrate 12 in continuous web form is directed from supply roll 10 through conventional dye bath 18 where a liquid dye is applied to the substrate web.
  • bath 18 is comprised of four rolls: a driven roll 20, roll 22, which is at least partially submerged in a liquid dye contained in dye trough 28, and opposed driven rolls 24,26, which form a nip of adjustable dimension.
  • Rolls 24,26 may serve two functions: (1) to pull the web through the bath and (2) to squeeze a desired portion of liquid dye from the substrate. The latter function is desirable under normal circumstances to remove excess dye for the purpose of subsequent re-use, as well as to minimize the energy necessary to dry and fix the dye on the substrate.
  • Nip rolls 24,26 also serve to adjust the moisture content of the substrate to vary the effects produced by the impinging jet used to pattern the substrate in accordance with the teachings herein. Of course, other dye bath roll configurations may be used.
  • jet array 100 is comprised of a series of parallel, closely spaced tubes 110 ( Figure 6) of relatively small diameter directed at the surface of substrate 12. Each tube is connected to a respective flexible conduit 112 through which pressurized gas is supplied. The outlets of tubes 110 are arranged at a uniform distance from the surface of substrate 12 within array alignment plate 122, shown in cross-section in Figure 6, which holds individual tubes 110 in rigid alignment as discussed hereinbelow.
  • tubes 110 are arranged in a linear array with minimal spacing between adjacent tubes.
  • One side of each tube 110 is positioned within an individual "V" shaped notch or groove along the lip of an alignment plate 122 which is fastened securely to array bar 134.
  • Opposite plate 122 is positioned pressure plate 124, which contacts the side of each tube 110 protruding from the confines of each "V" shaped notch or groove in alignment plate 122.
  • the action of pressure plate 124 and adjusting bolt 126 urging tubes 110 snugly into their respective notches in alignment plate 122 allows for rigid, repeatable alignment of the outlets of tubes 110 above the surface of substrate 12.
  • each tube 110 is bent to facilitate side-by-side tube arrangement having minimal adjacent tube spacing measured along the axis of alignment plate 122.
  • Tubes 110 each pass through a drilled passage in support plate 128, which, as shown, is attached to alignment plate 122 via attachment bolts 130.
  • the drilled passages of Figures 5 and 6 are depicted in a three hole, quasi-sinusoidal configuration; of course, other configurations may be used.
  • alignment plate 122, pressure plate 124, and support plate 128 may each be configured in relatively short, abutting sections which are attached to array bar 134 extending across the width of substrate 12.
  • array bar 134 is adjustably attached to articulated linkage 140, whereby the array may be adjustably positioned with respect to substrate 12 for patterning, changing substrates, cleaning of the array, etc.
  • Tubes 110 are each attached to individual conduits 112 through which is supplied pressurized gas of the desired kind. As discussed earlier, air at ambient temperature is preferred, but other gases may be used if desired.
  • each conduit 112 is associated with an individual valve, not shown, which is electrically or pneumatically controlled by externally supplied patterning information, thereby allowing the pressurized gas to flow through any individual conduit 112 and associated tube 110 and onto the substrate 12 only in response to pattern information.
  • the individual valves and perhaps the source of pattern information may be located in housing 70, as shown in Figures 1 and 2. To facilitate positioning the array close to the substrate for patterning but away from the substrate for maintenance, changing substrates, etc., housing 70, to which is attached array 100, may be mounted on sliding carriage 72.
  • substrate 12 which may have a pile face, as depicted, or which may be a flat fabric, is directed through an approximate 90° wrap angle around single support roll 30.
  • roll 30 is smooth and solid, but a foraminous or contoured roll surface may be employed if special patterning effects are desired. Wrap angles other than 90° may be used as desired.
  • the substrate to be patterned in this configuration be in contact with the support roll 30 at the point where the jets contact the substrate. This minimizes any tendency of the substrate to oscillate or flap in response to the jet impingement.
  • the gas jet may penetrate the substrate only to a depth of a fraction of a yarn diameter, or may penetrate the substrate until encountering an impenetrable barrier such as a back coating or the surface of the backing roll.
  • the jet is then redirected outwardly from the barrier and substrate.
  • the impact of the jet on the substrate causes redistribution of the liquid dye held by the substrate in the area of impact.
  • the liquid dye is "squeezed" from the substrate within the area of impact and accumulates as a drop or globule on the substrate surface, and is ultimately ejected by the momentum of the outwardly redirected jet.
  • Catch basin 92 may be used to collect and, if desired, recycle liquid dye ejected from the substrate.
  • the alternative apparatus configuration of Figures 2 and 4 is generally more suited to substrates which the gas jets will penetrate readily, and for which a principal dye removal mechanism will be via dye droplets blown entirely through the substrate and leaving the substrate from the back of the fabric.
  • the substrate is positioned opposite jet array 100 via a pair of spaced rolls 34,36 which leave the fabric unsupported, except for web tension, in the region of jet impact.
  • This unimpeded path through the substrate when used with an appropriately chosen substrate construction (i.e., one which is readily penetrated by gas jets of the kind contemplated herein) results in a substantial part of the impinging gas passing through the substrate, pushing or carrying droplets of liquid dye with it in the direction of catch basin 96.
  • catch basin 94 placed below the face of the substrate may be employed. If recycling of the dye is desired, catch basins 94,96 may be associated with dye recycling filters, pumps, etc., not shown.
  • the angle at which the gas jets are directed at the substrate may be adjusted over a wide range. It has been found that, although significant effects may be observed at any angle which allows the gas streams to impinge the fabric, a preferred impingement angle lies within the range of 0°to 60°, as measured from the perpendicular of the substrate at the region of impact, and as indicated by the angle in Figure 3. The measurement of the impingement angle in the embodiment of Figure 4 is similar. Impingement angles within the range of about 25° to about 45°, and particularly within the range of about 30° to about 40°, are especially preferred.
  • Figures 1 and 2 both depict a treatment zone 50 following the gas jet patterning station described hereinabove. It is contemplated that treatment zone 50 may be used for drying and fixing the pattern dyed substrate immediately following the patterning step and prior to storage of the pattern dyed fabric on take-up roll 60. As depicted, driven rolls 52,54 are used to assist in drawing the substrate web through patterning station and treatment zone 50 and onto take-up roll 60. If desired, of course, the patterned fabric containing unfixed liquid dye may be subjected to other treatments prior to drying and/or fixing.
  • jet array 100 The generation of uniform background shades upon which patterns may be imparted by jet array 100 may be achieved using the dye bath arrangement depicted at 18 in Figures 1 and 2, or by other appropriate means known in the art. It is contemplated that a wide variety of novel and visually attractive patterns may also be generated by jet array 100 acting upon a substrate which is non-uniformly dyed or, in particular, which is dyed in a pattern configuration immediately prior to exposure to jet array 100. Any technique for the pattern-wise application of dye to substrates may be used, so long as the pattern dyed substrate contains unfixed dye capable of being redistributed or removed by the action of an impinging stream of gas of the nature contemplated herein.
  • a tufted acrylic substrate of approximately 14 ounces per finished square yard, 19 stitches per inch and 25 tuft lines per inch was first padded with a conventional basic and disperse red dye solution. The wet pick up of the dye solution was about 60 percent based on the weight of the substrate.
  • the web of acrylic substrate was then passed through the treating zone of the apparatus at about 10 linear yards per minute wherein a plurality of orifices (0.023 inch inside diameter and 25 orifices per linear inch across the web) impacted patterned air at approximately 50 pounds per square inch gauge (p.s.i.g.) supply pressure.
  • the orifices were placed approximately 0.1 inch from the face of the substrate, at an impingement angle of approximately 35°.
  • Example 1 The procedure of Example 1 was repeated in all respects except the supply pressure was decreased to 30 p.s.i.g.
  • the photomicrographs of Figures 20 and 21 (0.38x and 1.9x, respectively) show diminished contrast as compared with the patterned substrate of Example 1.
  • Example 1 The procedure of Example 1 was repeated in all respects except the distance the orifices were located from the face of the substrate was changed to approximately 0.2 inch. As may be seen from the photomicrographs of Figures 22 and 23 (0.38x and 1.9x, respectively), increasing the orifice-to-substrate distance significantly degraded contrast as compared with the product of Figures 8 and 9, and Figures 10 and 11.
  • FIGs 7 and 8 Depicted in Figures 7 and 8, respectively, are alternative apparatus configurations for treating textile substrates in which a first set of gas jets (at 300) are used to apply a spray of liquid dye onto the substrate (Stage 1), and a second set of gas jets (at 100) are used to pattern the substrate by removing or rearranging the sprayed-on dye (Stage 2).
  • the gas jets 100 are intended to be reflected from the textile structure and the underlying backing member almost exclusively (as shown in Figure 3), while in Figure 8 the gas jets 100 are intended primarily to pass through the substrate, but with some of the gas being reflected by the yarns comprising the fabric substrate (as shown in Figure 4).
  • the apparatus of Figures 7 and 8 provide for either continuous pad dyeing, via the conventional pad dyeing arrangement depicted at 180 and comprised of driven roll 164, dye bath 178, and opposed driven nip rolls 168,170, or the gas jet-generated spray dyeing, via the arrangement depicted at 300, which arrangement is discussed in more detail below.
  • the user may elect, by appropriately configuring the path of the substrate web within the apparatus, to generate a solid background via the pad dyeing arrangement or generate a solid or patterned background using the spray dyeing arrangement.
  • Figures 7 and 8 show, diagrammatically, an overall side elevation view of apparatus suitable for patterning a web of moving substrate material using the Stage 1 and Stage 2 patterning processes in tandem.
  • the embodiment shown in Figure 7 employs a backing member positioned directly opposite the dye redistribution/removal array 100, as generally shown in Figures 7 and 3. This configuration is generally preferred if a relatively gas-impervious substrate is used, but may be used with other substrates as well. Where the gas jet from array 100 is intended to pass through the substrate, the substrate support arrangement generally shown in Figures 8 and 4 may be substituted.
  • Substrate 12 is supplied from any suitable source, e.g., roll 10, and is drawn over roll 150 and under roll 152 and valve house 250 to roll 156 which rotates in bearings fixed to platform 216. Substrate 12 is then directed into the interior of rolling frame 218, which is supported on wheels 212 and which may be moved along track 214 to adjust the distance between frame 218 and valve house 250, and, correspondingly, between arrays 300 and the surface of substrate 12. This permits easy and immediate observation of the effects of changing the spacing between valve house 250 (and the associated arrays 300 of spray generators) and the face of substrate 12.
  • any suitable source e.g., roll 10
  • Substrate 12 is then directed into the interior of rolling frame 218, which is supported on wheels 212 and which may be moved along track 214 to adjust the distance between frame 218 and valve house 250, and, correspondingly, between arrays 300 and the surface of substrate 12. This permits easy and immediate observation of the effects of changing the spacing between valve house 250 (and the associated arrays 300 of spray generators) and the
  • Substrate 12 is directed around roll group 230 and rolls 234,236 and through driven nip rolls 188,190, and is then presented, in a preferred embodiment, in a substantially vertical orientation to the multiple arrays 300 of spray generators mounted on the face of valve house 250.
  • the substrate 12 may be separated from an appropriate backing member 220, which may be comprised of plastic or other dye-impervious material, by spacers 222,224 positioned along the top and bottom edges of backing member 220 above and below the level of the spray generator arrays 300, thereby assuring no contact between the back of substrate 12 and the backing member 220.
  • lower spacer 222 may be in the form of a trough-like collector which can serve to collect the sprayed liquid dye which may pass through substrate 12 and collect on backing member 220.
  • Substrate 12 is then directed over backing roll 192 and over tension-generating roll 194, which may have a surface covered with rubber or the like and which may be overdriven to assure that substrate 12 is relatively taut in the region adjacent to arrays 300.
  • substrate 12 may then be guided to an appropriate dye fixation means 50 or other post treatment processor.
  • photoelectric cells may be used to determine the elevation of the catenary formed by substrate 12 between rolls 194 and 196, and thereby adjust the speed of the drive motor(s) associated with nip rolls 188,190 and roll 194.
  • Figures 9 through 16 collectively illustrate a preferred embodiment of the spray generator of the type depicted at 300 in Figures 7 and 8.
  • Figure 10 depicts a partial cross-section view along a vertical plane perpendicular to the longitudinal axis of array 300.
  • the elongate array 300 is comprised of a plurality of individual spray generators, each comprised of a dye pipe 330 and nozzle 332 through which a liquid dye, ink, or other marking material may be pumped, and a dispersing aperture 340 and associated surround 342, through which a relatively high pressure dispersing fluid, for example, air or other gas, may be propelled.
  • a relatively high pressure dispersing fluid for example, air or other gas
  • the individual spray generators are mounted in alignment, with an adjacent spacing appropriate to the degree of definition desired. It is believed adjacent lateral spacings of between about 0.2 inch and 1.0 inch, measured from the centerlines of adjacent dispersing apertures 340 along array 300, may be used with good results. Spacings outside this range may be used if, for example, minimal overlap between adjacent spray patterns on the substrate is desired.
  • each generator further associated with each generator is an electronically controlled valve 260 which is interposed in the pressurized air lines 264 and 266 which serve to supply the apertures 340 with pressurized air from manifold 270, which in turn is suitably connected, via regulator 276 and filter 274, to a source 272 of pressurized air.
  • Valves 260 are, in a preferred embodiment, of the electrically actuated pneumatic type such as those distributed by the Lee Company of Westbrook, Connecticut.
  • dye supply line 288 which extends from dye manifold 280, which is fed, via pressurizing pump 284 and filter 286 and associated conduits, from dye reservoir 282.
  • Dye conduits 292 and 294 supply reservoir 282 with excess dye from manifold 280 and captured dye expelled by nozzles 332 ( Figure 10) into containment trough 362, thus forming, in a preferred embodiment, a recirculating dye system.
  • elongated array frame 310 is constructed with a series of parallel "V"-shaped notches or grooves 302, 304, spaced along its length, in precisely opposed pairs along the top and bottom of frame 310 at intervals corresponding to the desired lateral spacing between adjacent dye pipes 330 and air conduits 314.
  • Air conduits 314 may then be placed within "V"-shaped grooves 304 directly opposite corresponding dye pipes 330, and attached to respective air lines 266 ( Figure 10).
  • dye pipe positioning plate 370 and air conduit positioning plate 320 respectively secured to frame 310 via laterally spaced bolts 380 and 385, maintain dye pipes 330 and air conduits 314 within their respective "V"-shaped grooves. Due to the self-centering nature of the "V"-shaped grooves 302, 304 (as compared with other possible groove cross-section shapes), no additional stream alignment technique is needed, provided grooves 302 and 304 have been placed directly opposite one another.
  • the array 300 comprising frame 310 and positioning plates 370,320, is suitably attached, via rigid member 290 and mounting bolts 384, to the front face 252 of valve house 200 ( Figure 10).
  • Air conduit 314 is fitted with a tapered coupling so that air at pressures of 60 p.s.i.g.
  • valves 260 may be transferred to replaceable port aperture 340 from supply line 266 (of which two are depicted in Figure 10, to indicate a suggested arrangement for accommodating closely adjacent lines 266), which in turn is connected to valves 260 via fittings 254 in front wall 252 of valve house 250.
  • air valves 260 are situated in close proximity to fittings 254, and may be arranged on a pneumatic circuit board analogous to an electronic circuit board.
  • Such pneumatic circuit board or "valve card” may be equipped with suitable mating fittings so that a valve card carrying a plurality of individual air valves for individually controlling a corresponding plurality of individual spray generators may be merely plugged into corresponding fittings 254 mounted on the inside of front wall 252.
  • a suitable number of valves 260 may be individually mounted on one such a valve card, with multiple valve cards mounted in adjacent fashion to provide control along the length of the entire array 300.
  • aperture 340 Associated with aperture 340 is shroud or surround 342, through which nozzle 332 may extend via surround port 344.
  • Surround 342 tends to maintain the high velocity of the dispersing medium jet formed by aperture 340 and to focus the jet in the direction of the substrate. Operation without surround 342 or a similar confining enclosure results in a process which generates an undesirable cloud or mist of dye which is difficult to control in terms of placement, degree of mixing of adjacent sprays, etc.
  • Nozzle 332 supplied with slightly pressurized dye via dye supply line 288 and dye supply manifold 280, is associated with pipe 330 which fits within "V"-shaped groove 302.
  • the relative position of nozzle 330 within surround 342 may be changed, as is shown in Figures 12 and 13, by moving pipe 330 within groove 302 and locking pipe 330 in the desired position by means of set screw 380 and the clamping action of positioning plate 370.
  • This adjustment has been found to alter the character of the spray by changing the radial distance from the axis of the air jet, and therefore the character (e.g., velocity, pressure, etc.) of the region within the air jet at which the dye is ejected from the protected confines of nozzle 332.
  • nozzle 332 may be located substantially above the axis of aperture 340, it is preferred that nozzle 332 be positioned within surround 342. In a preferred embodiment, the tip of nozzle 332 is positioned at most a short radial distance from the axis of aperture 340 so that, whenever the air stream associated with aperture 340 is actuated, the liquid emanating from nozzle 332 is immediately acted upon by the jet and does not have the opportunity to form a defined, coherent stream except during interruptions in the flow of air from aperture 340.
  • a diverting lip or surface 360 Perpendicular to the longitudinal axis of dye nozzle 332 and, in the embodiment shown in the Figures, generally situated opposite aperture 340 and parallel to array 300, is a diverting lip or surface 360.
  • Surface 360 is mounted so that dye exiting from nozzle 332 will, in the absence of a disturbing air stream from aperture 340, form a stream which travels in a trajectory which terminates on diverting surface 360 and flows into an associated containment trough 362, as shown in Figure 10. From trough 362, the dye may be pumped, via dye basin 364 and conduit 294, either back to dye reservoir 282 for re-use or to a suitable waste receptacle.
  • surface 360 may be mounted inside trough 362 to extend upwardly therefrom, and is preferably mounted via a suitable adjusting means so that the degree to which surface 360 extends into or beyond the path of the dye stream, as well as the relative spacing and alignment of the surface 360 with respect to nozzles 332 and surrounds 342 in array 300, may be adjusted. It is contemplated that surface 360 may be relatively rigid or, alternatively, may be a relatively thin, flexible blade which is given rigidity by clamping each end of the blade and applying suitable tension along the length of the blade.
  • Some dye is pushed downwardly into the collection trough 362, but some is pushed upwardly, toward the edge of diverting surface 360, and is ultimately pushed over the edge and is carried by the air stream toward the substrate, in the form of larger droplets and irregularly shaped spatters (i.e., the product of macroscopic fragmentation).
  • valves 260 associated with air supply lines 266 prevent air from passing through port aperture 340.
  • ink is permitted to stream from nozzle 332 to diverting surface 360 without interruption, as shown in Figure 10, where it is dissipated and collected in containment trough 362 and drip basin 364 and, ultimately, pumped back to dye supply manifold 282 in pressurized form or discarded.
  • Figures 12 and 13 depict the dye applicator in operation where pulses of air, generated by the rapid actuation and deactuation of valves 260, are being supplied to aperture 340.
  • Pressurized air entering conduit 314 and passing through aperture 340 forms a jet which interacts with dye which is continuously supplied from the tip of nozzle 332.
  • the resulting spray of dye droplets is directed onto the surface of substrate 12.
  • the tip of nozzle 332 is positioned within the region occupied by the jet, so that the dye is acted upon by the jet immediately upon its exit from nozzle 332. This position tends to suppress the formation of the relatively larger spatters, flecks, and blotches associated with macroscopic fragmentation, and tends to encourage the fine mist formation associated with microscopic fragmentation.
  • the stream of relatively low pressure dye typically about 0.2 to about 4 p.s.i.g.
  • the stream or jet of relatively high pressure air typically about 5 to about 60 p.s.i.g.
  • the ratio of dispersing material pressure (e.g., air) to marking material pressure (e.g., dye) will generally fall within a range of about 5 to about 60, but may fall outside this range under certain conditions. For example, if high viscosity marking materials are used, higher than usual dispersing material pressures may be desirable, causing the above ratio to exceed 60.
  • a variety of droplet sizes and mist is produced, which are generally propelled in the direction of the surface of moving substrate web 12.
  • Web 12 may be positioned typically from about two to about twelve inches from the tips of nozzles 332.
  • the adjacent spacing of the individual nozzles 332 and apertures 340 comprising the plurality of spray generators spaced along the longitudinal axis of array 300 is generally fixed for a given apparatus in order to maintain proper alignment.
  • This spacing is preferably such that, for a given nozzle-to-substrate distance, the spray patterns from immediately adjacent spray generators have substantially overlapping trajectories, allowing for the overlapping and mixing of the spray patterns throughout a significant percentage of the spray path between nozzles 132 and the surface of substrate 10, as depicted in Figure 14.
  • the included angle of the spray pattern may be on the order of about 25 to about 50 degrees
  • the adjacent spacing may be about 0.3 to about 0.6 inch
  • the nozzle-to-substrate distance may be from about four to about eight inches.
  • valves 260 controlling the flow of air to aperture 340 are actuated by means of computer control, which permits each of the individual dye streams to be selectively interrupted in response to externally supplied pattern data, thereby providing the capability of reproducing complex side-to-side patterns extending across the width of substrate 12.
  • This computer control may be associated with the computer control used in the Stage 2 dye removal/rearrangement patterning operation which follows this patterning operation.
  • Computer control may also be used to accommodate variations in dye pick-up or dye deposition requirements among different types of substrates, as well as variations in the speed of the substrate as it is drawn through the apparatus. This may be achieved in a manner similar to that disclosed in U.S. Patent Nos. 3,894,413; 3,969,779; or 4,033,154, or by other appropriate means.
  • jet array 100 is as described hereinabove in connection with the embodiments set forth in Figures 1 through 6.
  • Dyes or other marking materials having a wide variety of flow characteristics may be used with the Stage 1 dyeing technique described herein; generally speaking, higher viscosity liquids tend to increase the degree of macroscopic fragmentation which occurs, while lower viscosity liquids tend to increase the degree of observed microscopic fragmentation.
  • Various thickeners, thixotropic or pseudoplastic agents, surface tension modifiers, and the like have been used with interesting results. For example, use of agents such as guar gum which cause the liquid dye to become "stringy" causes the resulting pattern of dye on the substrate to contain a random line segment pattern element which somewhat resembles portions of a spider web, and which contains blobs or nodes of dye positioned at various intervals along the length of the line segments.
  • Figures 7 and 8 both depict a treatment zone 50 following the gas jet patterning station described hereinabove. It is contemplated that treatment zone 50 may be used for drying and fixing the pattern dyed substrate, as appropriate, immediately following the patterning step and prior to storage of the pattern dyed fabric on take-up roll 60. The nature of this treatment zone is dependent upon the composition of the substrate. As depicted, driven rolls 52,54 are used to assist in drawing the substrate web through the patterning station and treatment zone 50 and onto take-up roll 60. If desired, of course, the patterned fabric containing unfixed liquid dye may be subjected to other treatments prior to drying and/or fixing.
  • the fabric was then passed through the dye rearrangement/removal treatment, similar to that depicted in Figures 3 and 7, comprised of a plurality of air orifices mounted in a linear array having a lateral spacing of 25 orifices/inch and spaced 1/32 inch from the face of fabric, where air at 35 p.s.i.g. supply pressure removed dye in pattern form.
  • the fabric was then conventionally thermosol dyed at 380°F. for three minutes, washed, and dried.
  • the resultant pattern is depicted in Figure 24 (1.15X).
  • the areas impacted by the dye rearranging/removing air jets are shown as the lighter, leaf-shaped areas of Figure 24.
  • Figure 25 (10X) shows the fabric in cross section.
  • the right side of Figure 25 depicts an area of the resultant fabric that was overdyed in the spray dye treatment zone only.
  • the left side of Figure 25 depicts an area of the resultant fabric corresponding to a leaf-shaped area, which was overdyed in the spray dye treatment zone and where some of the dye was subsequently removed by the action of the rearranging/removing jets. Yarns on this left side therefore carry a lower concentration of the sprayed dye than do yarns on the right side.
  • the right and left sides therefore exhibit different colors, due to the different relative concentrations of the (same) dye which resides on each side.
  • liquid dye may be displaced or removed from a substrate in accordance with the teachings of this invention.
  • gas stream velocity, relative substrate speed, and orifice-to-substrate spacing have been found to influence appreciably the extent to which the impinging gas stream has sufficient energy to move or entrain a visually significant quantity of dye.
  • the graph of Figure 26 attempts to approximate the functional relationship between momentum flux and the percent of liquid dye removed from a dye-wet substrate of the type contemplated in the examples, for the case of a single jet. In the graph of Figure 26, it may be seen that increasing the momentum flux as by increasing gas stream velocity or decreasing the substrate-to-jet spacing, generally results in increased dye removal.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Coloring (AREA)
EP89303652A 1988-04-12 1989-04-12 Procédé et appareil pour décorer des matières utilisant des jets de gaz Withdrawn EP0337777A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US18040688A 1988-04-12 1988-04-12
US18040588A 1988-04-12 1988-04-12
US180405 1988-04-12
US180406 2002-06-26

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JP (1) JPH02118187A (fr)
AU (1) AU622655B2 (fr)
NZ (1) NZ228701A (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0457422A1 (fr) * 1990-04-30 1991-11-21 Milliken Research Corporation Procédé de décoloration de textile
WO2004038086A1 (fr) * 2002-10-25 2004-05-06 Tecnofil Srl Procede et dispositif pour teinture espacee

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3443878A (en) * 1963-12-04 1969-05-13 Halbmond Teppiche Veb Method of continuously dyeing textile webs and the like
US3529992A (en) * 1967-02-16 1970-09-22 Commw Scient Ind Res Org Apparatus and method for decorating sheet materials
FR2254667A1 (en) * 1973-12-17 1975-07-11 Hoechst Ag Fabric colour shading process - uses combination of reactive dyestuff and thermal surface treatment
US3950967A (en) * 1973-01-31 1976-04-20 Imperial Chemical Industries Limited Colouration process
US4019352A (en) * 1976-02-23 1977-04-26 Milliken Research Corporation Apparatus for the application of liquids to moving materials
WO1980002852A1 (fr) * 1979-06-11 1980-12-24 Tybar Eng Pty Ltd Application de liquide utilisant une alimentation commandee de gaz
EP0200378A1 (fr) * 1985-04-03 1986-11-05 Massachusetts Institute Of Technology Procédé pour créer des motifs dans des matériaux

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3443878A (en) * 1963-12-04 1969-05-13 Halbmond Teppiche Veb Method of continuously dyeing textile webs and the like
US3529992A (en) * 1967-02-16 1970-09-22 Commw Scient Ind Res Org Apparatus and method for decorating sheet materials
US3950967A (en) * 1973-01-31 1976-04-20 Imperial Chemical Industries Limited Colouration process
FR2254667A1 (en) * 1973-12-17 1975-07-11 Hoechst Ag Fabric colour shading process - uses combination of reactive dyestuff and thermal surface treatment
US4019352A (en) * 1976-02-23 1977-04-26 Milliken Research Corporation Apparatus for the application of liquids to moving materials
WO1980002852A1 (fr) * 1979-06-11 1980-12-24 Tybar Eng Pty Ltd Application de liquide utilisant une alimentation commandee de gaz
EP0200378A1 (fr) * 1985-04-03 1986-11-05 Massachusetts Institute Of Technology Procédé pour créer des motifs dans des matériaux

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0457422A1 (fr) * 1990-04-30 1991-11-21 Milliken Research Corporation Procédé de décoloration de textile
WO2004038086A1 (fr) * 2002-10-25 2004-05-06 Tecnofil Srl Procede et dispositif pour teinture espacee

Also Published As

Publication number Publication date
NZ228701A (en) 1992-03-26
AU3272689A (en) 1989-10-19
AU622655B2 (en) 1992-04-16
JPH02118187A (ja) 1990-05-02

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