GB2031032A - Textile Manufacturing Procedure with Synthetic Contribution - Google Patents

Abstract

A plastics coated textile material is made by weaving a textile web 2 continuously in a loom 1 from which it passes directly through an electric oven 4, via adjustable calenders 11, to be wound on spools 9, the whole process being carried out in a single production line. Additional webs may be applied to one or both sides of the textile web by calenders 11 as the textile web emerges from the oven 4.

Description

SPECIFICATION Textile Manufacturing Procedure with Synthetic Contribution The subject matter of this patent of invention concerns "Textile Manufacturing Procedure with Synthetic Contribution", which achievement makes possible the intended industrial purpose under the following advantages.

A. It cuts down the standard process of manufacturing of plastified clothes, carrying out in a single phase, all the operations of a standard process, in continuous process until its final storage.

B. It saves time, transport room and intervening storage, and labor, thereby cutting down the manufacturing costs.

C. It can be carried out synchronizing all the elements taking part in the process, including the rapid loom where the process is started.

D. Due to the use of a single set of elements, thoroughly synchronized and fitted each other, it makes use of the advantages or features of every component of the set, as direct and immediate application in the subsequent component or phase.

E. It keeps on the manufacturing speed in every and in each one of the parts making up the process, from its start in the loom until its completion for storage in spools.

F. It keeps and makes use of the starting voltage from the loom, both longitudinally or transversally all through the process, with the resulting saving on tightening devices for the several intermediate operations.

G. It makes possible, changing the different manufacturing factors, both in the raw materials to be used as in the factors relevant of each element or machinery making up the process, to achieve a huge range of processed products.

H. By changing the factors of the machinery (loom, furnace, calenders, etc,) and changing the raw material to be used (warp and woof) both in purely synthetic elements as synthetic mixtures (polyethylene, polyester, etc) or classic fibres mixtures, the processed products may be plastified textiles, strengthened textiles for sacks and coverings in the whole (transparent, translucent, dim, etc), light textiles floating in liquids, synthetic floors, textiles substituting leather or braided textiles for shoewear, etc.

This procedure is grounded upon two very important premises. The first one concerning the type and joining of the machinery to be used making up the whole of elements in the production line and whose interrelations are fundamental in achievement and manufacturing a certain product. The second premise is grounded in the features of the type of the initial product to be used, giving rise to a huge range of final products.

The production of plastified and waterproof textiles is grounded now upon a plastification operation of the already made textiles. Usually the factories or plants making plastically waterproof clothes, or having a production rising from textiles acquired from textile factories or looms, or their plastifying department is a division independent of the textile divisions. That is, they receive the cloth, already weaved and stored in huge spools and in a suitable machinery division it receives the wanted treatment in synthetic material. The clothes or canvas used are standard type, both in natural fibers (cotton, hemp, linen, etc) or artificial (synthetic fibers).

The subject matter procedure of this patent rises from the idea of a single production unit grounded on the juxtaposition and chaining of a loom, of a furnace and several calenders and other accesories, and whose operation in the whole is perfectly synchronized, in such a way that the properties of the product coming out from one of the phases are applied directly and immediately and under automatic form upon the following phase.

Thus, in order to use the recommended system, one starts from a loom that may be of an extra-fast universal type, with great production capacity, both on account of the outlet speed as on the total width of the woof. These types of universal looms, of high performance, may process or weave the material from all kinds of yarn as cotton, wool, cellulose fibers (threads and continuous), synthetic fibers (threaded and continuous), including elastomers and monofilaments, mixing fibers, jute, wires, glassfibers, etc. The range of qualities that can be achieved is very wide: the machine may insert a carded wool spinning No. 1 or No. 0.65 or a 1200 den small propylene ribbon with the same safety as done with a 12 dtex monofilament, and almost all the intermediate threads.

If such loom is being operated to weave fibers or threads with any synthetic component, or in the woof or in the warping, or in both at the same time, (the possibility of alternations of pure fiber with entirely or partially synthetic threads is not being set aside, in relation to the woof or warping), that is, that when there is some synthetic component in the processed textile, and that consequently it would be capable of changing its physical features because of the heat action, it can be Rightaway Applied in the outlet of the loom, a continuous electric oven, perfectly controlled in its factors, through which the cloth may pass through, keeping up a high outcome speed in the machine (loom) and taking advantage of the warping tightness.And the heat action, changeable according to the weaved fiber or to the ends to be achieved, will change the features of the synthetic component, being able to be welded if the woof and the warping (if both would have synthetic components), melt the covering synthetic component (making up a coat of synthetic material) if there would be used totally or partially (warping and woof or one or other) synthetic monofilament threads or natural fiber threads with synthetic covering. Thus, one can achieve quite water-proof plastified textiles, and depending on the degree and quantity of swellable additive that the used synthetic component may bear, before even of starting its cooling on leaving the oven, it may undergo a line work process by passing through some rollers in one calender, completing the product in some storing spools.

Out of the above general description, one can imply that a chain made up by a loom, calender oven, coolers and storage spools, may be set up, and all that operating under a very high outlet speed from the extra-fast universal loom and in over five meters widths, being able to reach with special looms and in terms of the type of thread used, up to almost ten meters widths.

This may give an idea of the huge output capacity of this set of elements. All of it by achieving the very best output performances:- High quality of the obtained products.

-The operation is carried out in a single line, avoiding intermediate transport and partial storage operations.

-The making speed is kept steady all along the length of the output line.

-A great variety on the range of products, changing the factors of the loom, the oven and of the different calenders and further line accessories.

-Saving of labor by total automatization of the different phases of the line.

-Saving of room due to the juxtaposition of the different elements making up the line.

Let us study now the different factors concerning the raw material used.

The threads used in the loom may be of different type. Basically, it is wanted the use of a thread having some synthetic component therein.

Thus, the thread used in the warp may bet 1. Classic thread without any synthetic material.

2. Synthetic thread with highly strength to the power haulage with different grades of reaction before heat.

3. Natural fiber thread cover with a synthetic component that may be affected by heat.

4. Bare wires or synthetically covered.

5. Bare glassfibers or synthetically covered.

6. Artificial threads.

7. Rubber threads or artificial synthetic gums.

As far as the woof, it can be used the same type of thread as previously described, adding low tightness or traction synthetic threads, monofilaments.

It is not advisable to use such threads in warping, since they cause deformations in the fabric, and they may have changeable stretch reactions in different areas of the fabric.

The threads used in the woof and in the warping may be uniform or of different type, basically those of the woof. There may be alternations between the threads, with total or partial contribution of fusible materials or threads without contribution of material that might be largely affected by heat.

A new variable may be brought into the raw material: a swellable additive may be added synthetic material liable to act under the action of heat, on passing through the oven.

Other important variant to be considered is the thickness of the thread to be used or the number of fibers making it up. There may be used fine monofilament threads, slightly braided threads with many of few filaments giving rise to very thin or very thick threads. They may be combined in one type of thread for the warping and different types in the woof, or different thickness threads in the same fabric alternately in the woof.

In what concerns the typical variants of the loom, there may be considered the space between the threads in the woof and the threads in the warping, giving rise to different forms of meshes. Tight mesh complex fabrics or wide mesh fabrics may be made.

As indicated, the process in general is based in the use of a certain feature loom, at whose outlet and immediately next to it, the setting-up of an electric oven automatically controlled and one final element rewinding the cloth thus obtained, by the changeable use of different elements such as calenders, auxiliary contributing spools, etc.

The fabric leaves the loom and enters through the oven mouth and without contacting any element thereof, that is being on smooth by the outlet tightness of the loom, it goes out through the oven mouth, all as it is shown in figure 1 of the attached drawing.

There might be the possibility that the loom itself has incorporated a heating device based on infrared rays. Such equipment would incorporate a range of rollers (25) through which the cloth or fabric that has been made in the loom itself will go by. All these elements or rollers will be inserted in the inner part of a body closed by a carcase (26) which is incorporated into the weaving machine itself This body has to be closed in order to avoid or counting down the heat leaks, the cloth entering this department of the loom through its mouth (27). After passing through the last roller (25), the cloth may be submitted to the action of some equipments of infrared rays emitting valves, that will heat the surface of the cloth that will have a thermoplastic component and will have the same effect as it happens in the external oven previously described. These equipments producing infrared rays (28) preceding the pass of the cloth through some last rollers (29) that may act as calenders and engrave the softened clothes.

Obviously, a certain manufacturing process may be carried out by using the infrared loomoven or the loom with the oven fitted immediately into its outlet, with the consequent passing of some or other calenders. The process may be combined with the two types of ovens giving rise to two consecutive heatings or the passing through the different types of calenders, the first set, the one innerin the loom, may be smooth, and the external one may be with relief drawings or the contrary or any other combination.There can be included in this system after the external tunnel, the accessories where a shrinkage bath, vaporizations, etc. are applied, consisting of a set of rider rollers (30) followed by a drum roller (31) rotating within a soaking vat (32); there can be fitted also devices to apply chemical products (latex, polyurethane, pvc, etc) with assistance of a vat (33) on leaving the oven.

Then, the weaved material is in the very best conditions to undergo, by the a pressing action by means of calenders, the addition of a synthetic material film on one or both sides of the textile, and the configuration of drawings by rollers, in form imitating certain furs.

The main products that can be achieved are: A. Water-proof textiles to cover loads (lorries, railway canvas, etc). The process is outlined in figure 1-1. The elements of the line are, the loom, the electric oven, the picking up spool, and a cooling element, that may be natural or forced byafan.

The raw material to be used may be natural thread for the warping or some heat-resistant polyester or propylene. Such thread may be bare or cover with low grade melting synthetic material with an incorporated swellable element.

The separation of the warping threads is the one corresponding to a thick cloth. The total thickness of the thread is between fine and average type.

The woofirtay be in covered thread (required condition if the warping is in thread lacking material affected by heat), in low melting point synthetic material and upon which an additive with swellable properties under heat action has been added. It may also be bear thread if the warping is in low melting point synthetic material covered thread with a swellable additive. The warping may also be mixed, that is, made up by a certain number of bear threads, not fusible core threads and heat affected lining with swellable additive, or unifilament threads affectable by heat, all of it in all the different possible combinations ofthradto-ttrread alternation in the woof.

Once the threads of the warping and the woof have been selected, the thread enters the loom (1), under the appropriate proportions. The cloth is being weaved according to the smoothness, width of material, etc. established factors.

Straight away after leaving the loom (2) there is established the entrance mouth (3) of the electric oven (4). The passing speed of the textile (5) through the oven is exactly the same to the loom leaving speed. The P.V.C., or low melting point synthetic material partially or totally making up the textile is heated in the oven (4) and is expanded and swelled by a physical-chemical reaction, covering the pores or interstices of the cloth, at the time that a wrinkled condition is achieved, the configuration of the cloth framing remains although rather altered. It may weave cloth with composite warping, that is high threads with low melting point synthetic linings and not covered low threads, and the same in what concerns the woof. Thus, there is achieved a cloth producing only a face to be altered by the electric oven heat action.In figure 1-2 there have been outlined the different types of clothes that are found or produced in the different phases of this process. The (6) is the cloth before passing through the oven; the (7) is the cloth with a single plastified face. The (8) is a cloth with the two faces plastified or swelled.

At the end of the process and before storing the completed product in spools (9) there may be a cooling area that may be natural because of the distance between the oven (4) and the spool (9) or by insufflation or cool air by fans (10). The product is picked up in some spools (9) at the same linear speed under which it leaves the loom.

B. Water-proof textiles for covering smooth areas loads or engraved with certain drawings areas. The process is outlined in figure 2-1, that is similar to figure 1-1, with the including of a group of calenders (11).

The process is similar until the cloth leaving the oven (cloth of one or two plastified faces), where there has been established in order to take advantage of the heat, immediately to the textile, and so that it does not lose its superface plasticity, a set of calenders (11) that may be smooth, with drawings to engrave a face or with drawings for the two faces, giving rise to a range of different products, from the one-faced smooth textile and unplastified on the other (12), or oneface plastified textile and however with drawing (13) up to both-faces plastified textile with/without drawing on both sides (14) and (15).

C. Strengthened textiles by strength woof and warpings, and transparent, translucent or opaques between woofs. There are textiles that can be used for making sacks or covering nurseries, swimming pools or any other element requiring sun-light and to be protected from the air or atmospheric agents. The manufacturing process is shown in figure 3-1 where some thin laminated material spools have been added immediately to the oven outlet and before the calenders.

The textile intended to be achieved is made up by an only large mesh, warping and woof in the same synthetic material, strong, little extensible by traction, although largely flexible, in unifilament thread in some cases. A synthetic material film is joined to such a textile on one or the two faces, the mesh acting in the way of the great consistency and strength reinforcement.

The raw material to be used in this case is a high melting point polyethylene or polyester thread, monofilament with no covering.

The textile (2) leaves the loom (1) passing straight away to the electric oven (4). Just at its outlet, on one side or in both sides at the time, there are spools (16) with material in fine plastic bands or films to be joined to the cloth arriving hot from the oven. The joining is made by pressure when such materials pass through some calenders (17) smooth, adjustable, where the following results are achieved -The threads of the warping are sticked to the threads of the woof by the heat action, that although it has not melted them, it has softened its surfaces.

-Heat affects the synthetic film that is being brought forward, that is being heavily sticked to the threads of the woof and of the warping, and the two films between each other.

The material leaving the calender already firmly joined is cooled in a natural way or in forced way, and is rewound to be stored.

In figure 3-2 one can note how the cloth will remain with the plastic plates adhered (18) and a detail of the joining of the woof to the warping (19).

It may be a variant to this process consisting in the use both in the woof as in the warping of great thickness multifilament threads. The joining calenders (17) will act more separated and if in such way air is insufflated, both synthetic material films will be sticked or welded to warping and woof threads but not between each other, making a whole of air pockets between the meshes of this open textile, making it very useful for different and diverse applications.

D. Complex woof and thick warping textiles with great thickness textile, covered with a great synthetic material coat, especially for flat surfaces floors, walls, etc.

The process is not but a generalization and variation of the previous ones. The weaving machine has to operate with many filaments threads largely interwoven among each other.

Thus, a thick cloth in the way of carpet is achieved, where by the combination of threads under low pressure point synthetic contribution, at least in one of the faces of the cloth leaving the loom, on passing through the electric oven becomes softened and just at the outlet this softened face is covered by a synthetic material thick plate (21), also softened the face contacting the textile and all of its being passed through a calender (1 1 ) that will heavily and closely joint both surfaces, getting a product in the way of tapestry with a heavily plastified face. Even before its cooling or by means of one of the rollers, of the joining calender, one can imprint on the outer face of the brought forward material, after the oven, a range of in relief drawings that will form special features upon thus obtained surface. The collection is light, flexible, flat little fragile, unstretchable, roll-up, etc. Specially for flat floors, indoor or outdoor sport rinks floors (according to their surface relief) etc. In figure 4--2 2 is shown the different phases of the process, the bear tapestry on leaving the loom, the synthetic coat tapestry on initially contacting (23) and the already decisively formed tapestry (24).

This Patent of Invention is feasible in any appropriate sizes and materials being liable of every kind of detail modifications provided that they do not change its foundations.

Note The own and new points of invention that are the subject matter of this application for a Patent of Invention in Spain, for twenty years are as follow;

Claims (21)

Claims

1. Textile Manufacturing Procedure with Synthetic Contribution, characterized because it relates among each other, under an immediate way and without transport and storage intermediate operations, a set of operations to be done by the use of a loom, an electric oven for continuous process, some more or less adjustable calenders, laminate material bringing forward spools, processed product coolingequipments, heating equipments of components that do not go through the oven, and finally the completed product rewinding equipment, all of it in a sole line, at the sale linear in all the points, and taking advantage of the outlet mechanical features of an element as income features of the following.

2. Textile Manufacturing Procedure with Synthetic contribution, according to previous claim, characterized because it can use as first element of the manufacturing line, a loom that may be of the extrafast and universal type, thus reaching a very high output speed in the line, and the possibility of an almost unlimited range of textile products.

3. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because immediately to the loom outlet a continuous process electric oven is installed, where the cloth leaving the loom enters through a mouth, being heated properly in its interior by means of the heat built up in electric resistors, controlled area to area, and leaves out through the other mouth of the oven, already heated, and ready for the next operation to be done immediately all at the same loom outcoming speed, and using the mechanical tension of the product weaved in the loom.

4. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because both the loom and the oven, as the remaining of the equipments necessary to fit into this chain made by these two basic elements, will be perfectly synchronized and automatized, the loom outlet linear speed and the tension of the woof determined by the textile on leaving the loom will be kept up along the different operations, finally being stored in spools, all in a continuous process, straight away from element to element with no interruption for partial transports or controls.

5. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the loom may work with very different types of threads both in making the warping as in making the woof, the warping and the woof liable to be made by monofilaments or multifilaments, fine or very thick thickness, separated each other by a large mesh, or tightened making a more compact textile.

6. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the warping threads may be in no synthetic natural fibers, in synthetic fiber little affected by heat, in natural core fibers with low melting point synthetic material coating, in bear wires and wires covered with low melting point synthetic material.

7. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the woof threads may be in no synthetic natural fibers, in fibers, in synthetic fibers much or less affected by heat, in natural core fibers or wires covered by low melting point synthetic material, in bear wires, etc.

8. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the textile can be made with simple or complexed woofs, where the coat with synthetic material to be affected by the heat, either in the woof or in the warping or in both at the time, in such a way that the synthetic material is presented only in one of the two faces or surfaces of the woven cloth.

9. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the warping as well as the woof may be carried out with a mixture of different threads, under an alternate form with/without contribution of synthetic material, with bear thread, or synthetic monofilament, or normal core thread with low melting grade synthetic covering.

10. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the low melting grade synthetic material may carry in its processing, a swellable component acting by the heat action extending its volume in one physicalchemical transformation.

11. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because it can produce plastified clothes in one or both faces, by the use of a warping made by natural fiber threads or synthetic fiber threads little affected by heat, fine or average thickness, bear or covered with a coat of a low melting point other synthetic material as PVC could be, upon which a predetermined value of a swelling substance under the heat action has been added, and similar types of thread can be used in the woof, in addition to synthetic material tmonofilament threads little resistants to heat by the incorporation of an element swellable to the heat action, and in such a way that in one of the faces or in the two faces of the cloth, that is obtained in a high performance universal loom, have low melting grade synthetic components with swellable additive, such cloth passing immediately to the loom outlet through a continuous electric oven, the smoothness of the woof and warping being kept as well as the loom outlet speed, and in such a way that the PVC or synthetic material of the surfaces is extended by the heat action and swelled covering all the pores, turning out a water-proof cloth in which surface there remains rather altered the mark of the woof and warping, the cloth leaves the oven being cooled and winded to be stored and delivered continuously without any interruption and at the same outlet linear speed of the loom.

12. Textile Manufacturing Procedure with Synthetic Contribution, according to eleventh claim, characterized because at the outlet of the electric oven some rollers or calenders can be arranged to smooth-the plastified face, getting a flat and smooth surface. Or if the calenders are provided with drawings, different relief surfaces can be obtained, including the imitation of special leathers or skins such a lizard, crocodile, etc., or shaping the outline of the shoes leather in the cloth itself in a full form, pending only of a later die-pressed.

13. Textile Manufacturing Procedure with Synthetic Contribution, according to first to tenth claims, characterized because there can be produced in the loom clothes made up by warping and simple woof, with synthetic materials monofilament threads, little affected by heat although a bit superficially with large meshes that immediately after leaving the loom and keeping their same linear speed and tension, pass through a continuous electric oven where a certain grade fiber is softened, the woof and warping being welded and such joining being completed after leaving the oven, when passing through some rollers or calenders, there being joined to such a cloth by one side or by both sides and before passing through the calenders, a thin synthetic material, band, PVC type or similar that may be transparent, translucent or opaque and that is slightly heated by the hot air leaving the oven and that for the purpose of calender pressing, is welded or adhered for good to the mesh weaved in the loom, and two films are sticked with each other in the interstices if it would have been made with contribution of material at both sides of the woven cloth. The material is cooled and stored in spools, all of it keeping the same outlet linear speed of the loom, and the same tension, the reached product can be used in similar jobs than the PVC film or similar, with the contribution of the great mechanical strength provided by the woven framing, among others its applications being form making sacks, nursery coverings, swimming pools, etc.

14. Textile Manufacturing Procedure with Synthetic Contribution, according to thirteen claims, characterized because both the woof and warping may be made by a great number fibers thick theads, in such a way that on receiving the two synthetic material bands after passing through the oven, and adjusting the calenders pressure, the two bands stick only to the framing and not between each other, getting in each framing some areas full of air that may be also caused by an artificial insufflate, reaching light textile with new properties as its floatability, heat and sound insulation, knock damping if used as wrapper, etc.

1 5. Textile Manufacturing Procedure with Synthetic Contribution, according to first to tenth claims, characterized because a great thick textile can be reached in the loom, by multiple woof and warping, as well as thread made up by many filaments and in such a way that part or all such threads have synthetic components heavily affected by heat, with/without contribution of swellable substances and in such a manner that at least in one of the faces thus woven, there are threads bringing forward synthetic low melting temperature, all the cloth immediately after leaving the loom, passing through an electric oven heating and softening one of its surfaces, immediately after leaving the oven, an acceptable thickness winding synthetic material press iron being applied upon such surface, whose contacting face with the cloth may be preheated, both surfaces being sticked by contact that it is completed by passing through some calenders immediately after the contribution of the synthetic band, getting a perfect joining with incrustation of both materials between each other.

1 6. Textile Manufacturing Procedure with Synthetic Contribution, according to fifteenth claim, characterized because the synthetic material brought forward into the woven cloth may have the opposite surface with a preestablished embossing or such embossing may be brought forward when passing through the set of calenders before the final cooling of the product, that can be carried out before the final winding to be stored.

1 7. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because the loom itself may have an inward heating system of the textile with synthetic contribution that can be carried out in a close compartment of the loom, in order to avoid heat leakage after passing through a set of rollers, the process can be finished off before leaving the loom and after the synthetic material being softened by some rollers or calenders that may stamp a drawing upon the plastified cloth or just smooth the cloth surface, as the rollers being smooth.

1 8. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims characterized because the system can consist in two heating equipments, one incorporated into the loom and another external, each other separated by a set of calenders internally or externally to the loom.

19. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because before passing through the last heating tunnel, the cloth may enter the set of rollers and also into a shrinkage bath vat, vaporizations, etc. before passing to drying through the external tunnel and storage.

20. Textile Manufacturing Procedure with Synthetic Contribution, according to above claims, characterized because after passing through one of the heating tunnels, it passes through a roller and drum within the relevant vat for the application of chemical products, such as latex, polyurethane, pvc., etc., in one single face, making the reaction foamy, swellable in the external tunnel.

21. Textile Manufacturing Procedure with Synthetic Contribution, such as described in the foregoing specification and for the purposes specified therein.