JPS61266634A - Method and apparatus for producing spool having weft yarn dyed by indigo dye wound therearound - Google Patents

Abstract

Methods and machines for obtaining weft yarns on weaving spools are described and claimed. These yarns are cotton threads which are real indigo dyed and principally destined for the weaving of blue-in-blue denim. The weft yarns are obtained from warp yarns by special rebeaming and isolating steps. A new flanged weaving spool is made by injection molding and comprises two geometrically similar halves cemented together.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates in principle to the weaving technique of fiber fabrics. More particularly, the present invention relates to a novel and useful method of preparing weft spools of indigo dyed yarn for feeding weft yarns to known looms.

The invention further relates to a new and useful device for carrying out the method and to a special weft disc bobbin.

[Conventional technology]

Fabrics dyed with indigo dyes are well known and widely used in outer garments such as blue jeans made from "true indigo denim." Those skilled in the art will recognize that such "true indigo denim is not woven. It is well known that it is not possible to produce fabrics by dyeing them with indigo bat dyes. ``True indigo has certain inherent wear characteristics that are desirable and closely related to its particular manufacturing mode.''

This manufacturing process, which is well known to those skilled in the art, consists of an indigo dyeing process for the warp, so-called slasher dyeing or chain dyeing, and a denim weaving process using undyed or bleached cotton yarn as the weft. ing.

It has not been technically possible to obtain indigo-dyed weft yarns from the aforementioned indigo-dyed warp yarns, and it is also technically impossible to dye the yarns wound onto spools in a dyeing machine using an indigo vat dye. is not possible, so
Undyed thread was used. These facts are well known to those skilled in the art.

However, there is a strong demand for denim fabric whose weft yarns are dyed with true indigo.

Of course, it is not impossible to offer weft yarns dyed with non-vat dyes, such as naphthol dyes, but consumers will not accept fabrics dyed with anything other than indigo.
There is a strong desire for denim outer garments made of blue-in-blue true indigo denim, ie, denim dyed with indigo bat dye in the warp as well as the weft.

The prior art does not disclose the problems associated with the production of indigo-dyed weft yarns.

US Pat. No. 2,889,120 describes a machine for winding a series of bobbins or self-retaining tips for sewing machines. British Patent Specification No. 340,978 describes a warp beam for processing artificial silk threads.

The same GB Patent Specification No. 645,591 teaches an improvement in sectional beams for warp threads. Other publications also disclose winding for mechanical treatment of warp threads.

None of these publications discloses anything about the problems posed by indigo-dyed weft yarns, nor does it give any teachings on how to obtain such weft yarns.

[Means for solving problems]

A first object of the invention is to provide a method for producing a spool of weft yarn dyed with true indigo and ready for use in weaving true blue-in-blue denim etc. with warp yarns also dyed with indigo. There is a particular thing.

Another object of the present invention is to provide the above-mentioned method, which allows economical operation without long stops, for example due to thread breakage, and which does not generate unnecessary waste.

Yet another equally important object of the invention is to provide a simple and efficient apparatus for carrying out the novel method described above, whereby a weaving spool wound with indigo-dyed weft yarns is can be manufactured with high yield and low waste rate.

Another object of the invention is to provide a novel disc spool as the final yarn bobbin, on which is wound an indigo-dyed weft yarn and used in the method and apparatus of the invention.

The present invention first produces a weaving spool in which an indigo-dyed weft yarn is wound around a flange bobbin or disc spool.

Dyeing of warp threads with indigo bat dyes is described, for example, in Swiss Patent Specifications Nos. 612,557 and 613,333, and in "Textil Feldlung" published in 1975.
(Texti 1veredlung) 313-3
P on page 17.

It is disclosed in an article by Richter (P.). According to these publications, the warp threads are dyed with indigo by one of the processes called chain dyeing and slasher dyeing.

In chain dyeing, a rope is formed with 300 to 400 warp threads, several ropes are dyed in an indigo pat dye solution at the same time in a horizontal position, and the indigo is dyed when passed between a series of dyeing tanks. Expose the rope to air for oxidation. This rope is then washed, dried and warped. The length of each rope on the warping bobbin is about 10,000 m.

In the Thrasher dyeing method, thousands of threads are arranged horizontally to form a sheet-like structure which, if dyed as described above and a warped beam is used, is Layer these sheets on top of each other and roll them up.

The above-mentioned basic idea of the present inventor, ie, the idea of making weft yarns from dyed warp yarns, is extremely difficult in practice. This is because, if a package wound on a bobbin obtained by either of the above two methods is processed to obtain a single yarn spool on a weaving spool, one of the yarns in the dyed rope This is because the various threads are twisted together and intertwined with each other, and if you try to separate them, the threads will break. Additionally, the 300 to 400 spools required to wind each single thread in the rope require more space and warmth than is normally possible.
Each spool requires its own drive means, resulting in great technical complexity.

According to the invention, a plurality of yarns are first wound simultaneously as a group of yarns of the same number on a set of intermediate spools, and then the yarn groups on each intermediate spool are individually wound as a second step. by separating each single yarn thus obtained onto a weaving spool,
It has now been found that these difficulties can be overcome and weaving spools wound with indigo-dyed weft yarns can be produced starting from unwinding the warp yarns on rope spools or warping beams. Preferably, the plurality of weaving spools are arranged on the same substantially horizontal shaft.

If the weft yarns are prepared from ropes of indigo-dyed yarn by chain dyeing, the auxiliary spools (ie intermediate spools) receiving said groups of yarns are preferably arranged side by side on a common shaft. When these spools are filled with thread groups formed by dividing the original thread rope into equal numbers of threads, the auxiliary spools are removed from their common shaft and the individual threads on each spool are separated one by one. Preferably, all weaving spools which are separated and wound onto flanged weaving spools and which are necessary for this final stage are mounted side by side on the same shaft.

It has been found to be highly preferred that the division factors of each unwinding stage are chosen to be within ±25% of the same value. This split fax, evening is spool width,
Number of spools and each ^1 for this method! It is defined as the product of the yarn speeds in the product. This will be explained in detail later.

In a first step of the method described above, the auxiliary spools are arranged side by side on a common shaft and fixed thereto by means such as lateral gripping with screws or a key and keyway pair. Number of threads per spool x
The individual auxiliary spools carrying a yarn length of approximately 10,000 m are preferably metal (aluminum) spools with a hollow cylinder as the core and parallel circular plates as flanges.

The second stage of the process was surprisingly carried out without the expected difficulties in separating the filaments into 30-50 filaments. This is presumed to be because the first stage is stable and free of entanglements.

In the second stage of the invention, the tension of each thread on the intermediate spool varies so much that a conventional spool winder cannot be used. Therefore, if a conventional spool winder is used for this purpose, thread breakage will inevitably occur. The spool winder must be equipped with complex electronics for increasing the winding speed and electronic brakes for gradually varying the braking force on the intermediate spool, both connected to computer control means.

Therefore, the second stage of the furrowing method is carried out using a new flanged weaving spool capable of holding approximately 10,000 m of weft yarn required for normal weaving, by means of a special spool winder. is preferred. It has been found that, despite the presence of flanges, it is possible to easily draw the weft yarn from this new flanged spool without any noticeable increase in friction at the flanges. This is believed to be because the threads that are pulled out form a balloon, and the threads are pulled out radially rather than tangentially.

This effect was completely unexpected.

The invention also relates to a special flanged weaving spool suitable, but not limited, for use in the aforementioned method. This weaving spool is made of synthetic resin and has a first half with an axial hollow cylindrical bushing and a radial circular ring-shaped flange (an axial hollow cylindrical bushing and a radial circular ring-shaped flange). a second half having a flange;
The half bushing has a length equal to the thickness of the first bushing plus one flange, and its outer diameter fits into the inner diameter of the first bushing, and the two are bonded or welded together. has been done.

The flanged weaving spools required to carry out the second stage of the method of the first embodiment are slid one after the other on a suitable drive shaft without intermediate washers and are then gripped and fixed to the shaft. This shaft is then driven by a hydraulic motor, which produces a force of 40-150 mN per thread.
, preferably 50 to 3QmN, X number of winding yarns (1!Il
The winding force (i.e., the number of spools per shaft) is given.

The working speeds obtained reach 200 m/min in the first stage, when the thread is wound onto the auxiliary spools, and 300 m/min or more in the second stage, when the individual weaving spools are wound.

The flanged weaving spool is preferably made of a thermoplastic, strong, processable, smooth synthetic resin such as nylon, polyester, ABS (acrylonitrile-butadiene-styrene-copolymer), polycarbonate, or other polymer or copolymer. Due to the special design of the spool of the present invention, it is possible to use one and the same die to form two types of bushings with different diameters, changing only the internal mandrel.

When dyed warp yarns are obtained by the Thrasher dyeing method, the dyed yarns are beamed up onto a warping beam in the shape of the future warp yarns, that is, thousands of parallel warp yarns wound in "layers". The present invention has the task of also producing a weft yarn from this wound body.

This objective is achieved by introducing the necessary amount of auxiliary yarn for the weft into the warp row before the dyeing process, removing it separately from the warp after dyeing and winding it up simultaneously and at the same speed as the warp. Another embodiment of the method is to form a warp beam as described above without separating the weft yarns, and upon re-beaming of the original warp yarns obtained after the dyeing process, on said flanged weaving spool. The process consists of taking out the weft yarn and repeating this re-beaming and weft removal two or more times.

This method is characterized by the fact that there is no yarn tangling in slasher dyeing and because of the relatively slow working speed regulated by the maximum dyeing speed, yarn tangling on the warping beam during formation is prevented. It was developed based on the discovery of

EXAMPLES Hereinafter, the present invention will be described in more detail based on preferred embodiments shown in the drawings.

FIG. 1 shows an indigo-dyed rope 12 wound on a rope bobbin 0. The process of indigo dyeing itself is not part of the present invention and is well known to those skilled in the art. Note that the present invention is not limited to application to indigo dyeing of fiber bundles or filamentous materials, but is applicable to all cases in which wefts are extracted from warps. The rope 12 is about 7.5 to 16 NE for denim,
Preferably 12NH count indigo dyed 41
It is made up of 6 cotton threads. The length of the rope is approximately 1000
It reaches as far as 0m.

This rope is unraveled and simultaneously divided into 13 beams with 32 threads. A subsequent second rebeaming is repeated twice at the same speed as the first, so that 42 rebeaming spools are obtained.
These aspects have been selected. Any greater number of spools would require a disproportionate amount of space.

Groups 14 with 32 threads each are created by a grid 16. This grid 16 is threaded with each group of threads that were manually divided at the beginning of the rebeaming operation. The yarn bundle 14 is further smoothed by at least one other grid 18. Only one grid 18 is shown in the figure. Other known separation and smoothing means may be used instead of these grids.

The yarn bundles 14, each having 32 at, are simultaneously wound onto the auxiliary spool 20. This auxiliary spool 20 is attached to the shaft 22 by fastening means 24. By means of a motor 26, which is a driving means having a constant torque,
The shaft 22 rotates reliably.

In FIG. 2, the second stage of the rebeaming method is represented as a plan view of the device.

An auxiliary spool 20 is fixed to the shaft 30. This shaft 30 is decelerated by braking means (not shown) as required. The thread bundle 32 on the spool 20 with a thread length of approximately 10,000 m is separated into single threads 34 by the grid 36, which are led to the flanged spool 42 by the eye-left guide 38,40. On the shaft 44, three
Two spools 42 are arranged side by side. The shaft 44 is driven by a hydraulic motor 48, with the pressure oil inlet and outlet indicated at 50. Since a winding force of approximately 7ON (for 12NE thread) is maintained on each spool 42, the hydraulic motor 48 is required to provide a constant torque.

Each flanged spool 42 receives a winding of approximately 10,000 meters of single yarn, and 42 spools are arranged in parallel on the shaft 44. Only the two outermost spools 44 are shown in FIG. Winding is initiated by pinching the tip of the thread between flanges of adjacent spools. This starting end becomes the tail thread when the spool is full. This tail thread is therefore directly accessible and can be tied to the starting end of the next weaving spool to prevent interruption of the weaving process.

It is desirable to insert a known thread breakage stop device into the thread path shown in FIG. This monitoring device is not shown in FIG.

FIG. 3 shows a side cross-section of the flanged weaving spool of the present invention. This structure was new, and it was surprising that this spool could be used in a loom.

This spool 42 consists of two parts made by injection molding of thermoplastic synthetic resin.

namely, an inner portion 52 and an outer portion 54. The dimensions of the radial flange and the axial hub are selected such that when the image parts are assembled, the shape shown in FIG. 3 is obtained. The image portions 52.54 are then glued together with their cylindrical contact surfaces 56,56' forming a compact, durable spool body.

In carrying out the above process, two rebeamings are performed and the thread splitting factor at each stage is not necessarily the same. For example, this factor is 13:1 in the first stage mentioned above.
and 32:1 in the second stage. If the product of spool width, number of spools and thread speed at each stage is similar, especially within a difference of ±25%, the whole process yields the best result, i.e. the best mechanical efficiency, space efficiency. It was found that it increases labor efficiency. (Of course, a reasonable division factor that does not cause difficulty in winding can be predicted.) Next, an example of the calculation will be shown. The width of the auxiliary spool in the first stage is 175, the number of spools is 13, and the thread speed is 200.
m/min. This results in 4.55 x 10'w,
The product of m/min is given.

On the other hand, 42 stages (spool width 50 dragons, number of spools 42,
At a yarn speed of 300 m/min), it is 10'mm.

This is the product of m7. If the thread speed in the second stage were to be increased even further as normally possible, one skilled in the art would be taught to increase the number of spools in the first stage to 14 and reduce the number of spools in the second stage to about 30. There will be. (The number of threads in the rope can be chosen arbitrarily and can be increased up to 14×13=420.) Therefore, the product is:

P l =175XI4X200=4.9
XIO'm, mm/min Pz =50X30X325
= 4.88X10 Smyw/min (if the speed in the second stage is chosen to be 325 m/min) The optimal speed can also be calculated by substituting Pl in the first equation for P2, and the obtained V is the second stage speed. The speed will be .

P+ and Pz represent the essence in the first and second stages, respectively.

FIG. 4 is a schematic side view of a system for indigo dyeing of warp threads according to the principle of Thrasher dyeing, including means for separating and producing the weft threads. This diagram is highly simplified and only illustrates the general procedure of the invention.

This indigo dyeing machine is indicated at 60 and the washing and drying equipment following it is indicated at 62. The dyed warp threads are
It is unwound from the warping beam 64.66, combined, dyed and post-processed, then split and wound up into two individual weaving beams 68.70. This method is already known from Swiss Patent Specification No. 612,557 mentioned above.

According to the invention, a further beam 72 is provided, which supplies the weft threads with a horizontal distance of the order of 5011 between adjacent weft threads. These weft threads are processed together with the warp threads in the machine 60, 62, separated from the upper warp layer 74 on leaving the machine, and finally wound up separately onto the flanged weaving spool 42. These weaving spools 42 can be used as they are as a weft supply source without rebeaming.

The weft yarns may be arranged at even smaller intervals. For space saving purposes, the number of weft threads should be no more than three times the number of flanged weaving spools on the spool shaft. In this case, it is necessary to use deflection means such as an eyelet bar as shown in FIG. 4, for example.

Finally, FIG. 5 is a schematic side view of a device for extracting weft threads from warp threads.

The warp beam 80 has warp threads that have already been indigo dyed by a Slasher dyer. Parallel yarn layer 82 is re-beamed in the direction shown by arrow 84 and deflection rollers 88,
90.92 and is wound up on the empty beam 86.

The drive and separation means are not shown in this figure. As previously described, the individual threads are removed and wound onto a flanged weaving spool 42 secured to a shaft 44.

The total number E of threads taken out is 0×B E=− (where B is the width of the thread layer 82 and b is the width of the weaving spool). When the yarn on beam 82 is re-beamed to beam 86, the number of weaving threads is E.

A new weaving spool shaft 44 carrying an empty weaving spool is then inserted and the remaining yarn layer on beam 86 is wound onto the empty beam 80 in the direction of arrow 94.

This operation continues until all of the yarn on beams 80 and 86 has been transferred to weaving spool 42.

The objects of the invention can be achieved not only by the examples described above but also by equivalent modifications thereof. For example, the aforementioned hydraulic motor for driving the shaft of the flanged weaving spool can also be replaced by other drive means controlled by electronic means.

The auxiliary means of the device described above are well known to those skilled in the art and are not necessarily all shown or described.

[Brief explanation of the drawing]

1 is a plan view of a first rebeaming system of the invention comprising a first stage; FIG. 2 is a top view of a second rebeaming system illustrating a second stage of the method of the invention; FIG. FIG. 4 is a side sectional view of a flanged weaving spool of the present invention; FIG. 4 is a side view of a system for simultaneous indigo dyeing of warp and weft yarns by the slasher dyeing method; FIG. 1 is a side view of a rebeaming system for extracting . 10--Rope bobbin 12- Rope l4--Thread group 16.18-Grid 20-Auxiliary spool 22-Shaft 26-Motor 30--Shaft 34-Single thread 36-Grid 42--Flanged weaving Spool 44 - Shaft 48 - Hydraulic motor patent application agent

Claims (1)

[Claims] 1. A method for obtaining an indigo-dyed cotton weft wound on a spool ready for weaving, comprising: (a) a yarn bundle containing a plurality of indigo-dyed cotton yarns; ,
dividing into a predetermined number of groups each containing the same number of threads; (b) simultaneously winding the thread groups onto auxiliary spools arranged side by side; (c) separating individual single yarns within each thread group; d) A method comprising the step of winding the separated single yarn as a weft on weaving spools arranged side by side on the same axis. 2. The method according to claim 1, wherein the weft yarns are obtained from a warp rope dyed with indigo, comprising: (a) dividing the rope into a predetermined number of groups each containing the same number of yarns; b) winding the threads simultaneously but separately onto auxiliary spools fixed side by side on a single shaft; (c) removing the auxiliary spool from the shaft; (d) winding onto the auxiliary spool; (e) winding each of said individual yarns onto a flanged weaving spool fixed with other spools on a common shaft; Step (a) and (
A method in which the dividing factor of d) is selected in such a way that no trouble occurs during the separation of the yarn or yarn bundle. 3. The division factors of the steps are such that the product of the number of spools, the width of the individual spools, and the winding speed as an indicator of the amount of yarn fed per unit time is the same within a tolerance of ±25%. The method according to claim 2, which is selected as follows. 4. A method for obtaining spooled indigo-dyed cotton yarn ready for weaving, with at least two warp layers formed by a plurality of parallel warp yarns arranged in parallel and spaced from each other. A method comprising the steps of dyeing the undyed weft yarns by slasher dyeing technique, separating the weft yarns from the warp yarns after dyeing, and winding the weft yarns separately onto parallel weaving spools. 5. A method for obtaining spool-wound indigo-dyed cotton yarn ready for weaving, comprising: (a) a plurality of parallel indigo-dyed warp threads as a yarn layer formed by a plurality of parallel warp threads; (b) winding the unwound yarn layer onto a second beam; (c) taking out a predetermined number of single yarns from the yarn layer during unwinding; (d) ) Winding the taken-out yarns individually onto weaving spools arranged in parallel on parallel axes; (e) Reversing the unwinding direction of the yarn layer and replacing the full weaving spool with a new empty spool; (f) repeating step (e) until substantially no warp threads are present. 6. A weaving spool used in the method for obtaining indigo-dyed cotton yarn, the first half having an axial hollow cylindrical bushing and a radial circular flange;
a second half having a hollow cylindrical bushing in the axial direction and a circular flange in the radial direction, the bushing of the second half having a flange of the same length as the bushing of the first half; It has a length including the thickness and an outer diameter that fits into the inner diameter of the first bushing, both halves are made of synthetic resin, and the bushings of both halves are integrally bonded or welded. spool. 7. The spool according to claim 6, wherein the synthetic resin is an acrylonitrile-butadiene-styrene copolymer. 8. Apparatus for obtaining weaving spools wound with weft threads ready for weaving, comprising: (a) a yarn rope supply spool, a grid or eyelet bar, a plurality of yarn rope supply spools, grids or eyelet bars, fixed in parallel to a common winding shaft; a first re-beaming station comprising an auxiliary spool; (b) a group supply spool identical to said auxiliary spool, a grid or eyelet bar, comprising a plurality of flanged weaving spools fixed in parallel to a common winding shaft; Apparatus comprising at least one second rebeaming station. 9. A device for obtaining a weaving spool wound with weft threads that can be used immediately for weaving, including a warp beam wound with warped warp threads, and a winding device for winding up the warp threads unwound from the warp beams. Apparatus comprising a plurality of shafts carrying a take-up beam and flanged weaving spools disposed in the travel path of the warp yarns from the warp beam to the take-up beam. 10. Apparatus as claimed in claim 8, wherein said common winding shaft comprises constant torque central drive means. 11. The apparatus of claim 10, wherein said central drive means is a hydraulic motor. 12. The apparatus of claim 9, wherein said shaft comprises constant torque central drive means. 13. The apparatus of claim 12, wherein said central drive means is a hydraulic motor.