US1717633A - Process of and apparatus for blending textile fibers - Google Patents

Description

D.STEVENS June 18, 1929.

PROCESS OF AND APPARATUS FOR BLENDING TEXTILE FIBERS Filed April 4, 1927 2 Sheets-Sheet 1 June 18, 1929. STEVENS 1,717,633

PRocEss OF AND APPARATUS FOR BLENDING TEXTILE FIBERS Filed April 4, 1927 2 Sheets-Sheet 2 Patented June 18, 1929.

PATENT. OFFICE.

DEXTER STEVENS, OF ESMOND, RHODE ISLAND.

PROCESS OF AND APPARATUS FOR BLENDING TEXTILE FIBERS.

Application filed April 4,

This invention pertains to a processof and apparatus for mixing and blending fibrous materials preparatory to the manu' facture of textile yarns and fabrics. For the production of certain types of textile fabrics it is necessary to mix or blend two or more batches of fiber in order to obtain the requisite characteristics or to secure uniformity of color, quality, feel, etc. throughout the entire product. For example, mixtures of cotton fiber with wool, hair, silk, etc., are frequently employed as well as mixtures of fibers of the same kind, for example, cotton but of different staple or which have undergone different preliminary treatments. Likewise fibers of thesame or different kinds but differently colored are frequently mixed to produce intermediate shades or tints or to give mottled effects while, on the other hand, it is essential even when the fiber employed is all of the same kind, quality and color, to open out the fiber as received at the mill (whether in bales, sacks, or other form of package) and to mix it thoroughly before it is spun into yarn in order to produce yarn of uniform quality.

While many processes of and machines for mixing textile fiber are well known, I have found that many of the usual processes, even if productive of reasonably good results, consume an undue amount of time and power, and demand the use of machines or appliances which occupy a great deal of floor space, while such. machines and appliances are often of very expensive character.

The principal object of the present invention is to provide an improved process of mixing and blending fiber and mechanism for use in the practice of the process, both process and mechanism being simple and relatively inexpensive and requiring but little floor space, as compared with the usual blending processes and apparatus, while at the same time producing a more thorough mixing and blending than any process or apparatus heretofore known to me, the new process and apparatus being fully capable of mixing fibers of different colors so as to produce an even distribution of the color in the mix, this being one of the most difficult operations to perform successfully which is encountered in the preparatory stages of textile manufacture.

1927. Serial No. 180,654.

My improved process comprises a plurality of steps and may bevaried in minorparticulars in accordance with the kind and character of the fiber, the purpose to which the mixed fiber is to be put, and the condition of the fiber as received at the first stage of my novel process For example, if it be desired to mix batches of red and white fiber, the two batches mayaconveniently be dumped together into the feed hopperor bin of any one or more of the usual preliminary textile machines such, for instance, as bale breakers, openers, pickers, or'feeders, which tend to open out'andloosen the fiber. While such machines are often described as mixing the fiber, it should be remembered thatnone of thesemachines is operating upon more than a few pounds of fiber atany given instant, and while tosome extentsuch machines do mix the fiber which at any given time is within their range of action, they can not be depended upon to blend and produce an uniform mixture throughout a mass running into hundreds and even thousandsof pounds, and which passes through the machinein a stream of relatively small volume.

Having thus opened up the fiber and separated it into small masses or fl0cks,as is usual in textile practice, the first essential step in my new process is to spread a thin broad layer of the opened fiber evenly upon a substantially horizontal floor, table, endless belt, or creeper, such belt or creeper being preferred for reasons hereinafter described.

Preferably, though not necessarily, the spreading of the fiber is done pneumatically by delivering the fiber into an air blast from which the fiber is permitted to settle down by gravity onto the floor, table or belt in much the same way that snow accumulates upon the ground. Thin first layer of fiber is followed by a second very thin broad layer similarly deposited, and this by a third, and so on until the accumulated fiber has attained a substantial depth forming a pile, heap o1 drift preferably from three to five feet deep. If the fiber be deposited pneumatically, as above suggested, there need be no actual interruption between the laying of successive strata or layers, and in fact the strata normally merge imperceptibly into a each other by continuous fall of the fiber CTI ' usual so-called mixing machines.

particles upon the accumulated mass below. However, it is to be remembered that the drift or heap necessarily represents the summation of theincremental portions of fiber which at any given moment are falling upon the upper surface of the pile.

Assuming that this heap, or drift of superimposed strata'has thus been built up, I next proceed to remove from one face of the drift or heap a thin substantially vertical slice or section, delivering the fiber thus removed by mechanical or pneumatic means'to the next machine or process involved in the system of manufacture in which my novel process is interpolated. It must be evident that such a vertical slice, taken from the side face of the'pile may be considered as, and in fact, is, composed of a series of narrow strands, ribbons or hands, one from each of theseveral laminae or layers constituting the heap, and may thus be regarded as constituting an average sample of the entire mass. It is to be remembered that each layer is deposited (preferably by distributing a given and relatively small quantity of the fibrous material over a broad horizontal area) is qu te thin. Thus for example, if'the fiber be well separated: and flocculent, such a layer, may conceivablybe only a few fibers thick, and, it is evident that such a vertical slice, particularly if quite thin horizontally, constitutes as nearly a perfect representative mixture of the large body of material constituting the entire heap as could Well be obtained. Since such a'vertical slice is thus representative of the entire mass, it follows that by continuing to remove such thin vertical sections or slices from the mass and delivering such slices successively to the next machine or operation I may obtain a nearly perfect miX-,

ture of the material. Thus, by making the heap of large dimensions, that is to say, for example, making it to consist at anyinstan't of several hundred pounds or more of fiber, it is evident that a much more uniformmixture can be obtained than by any of the I may also continue to remove and deliver vertical slices from the pile until the entire pile is used up, and I find, for example, that if I deliver such successive slices directly to a carding machine, the resulting sliver from such carding machine is of uniform character and in. the instance above cited, contains red and White fibers in the desired proportion and, so uniformly distributed as to produce a yarn of extremely uniform shade.

Asthus far described the process would be intermittent, but in order that it may be continuous I may proceed either by build 'ing up oneiheap or pile While slicing off a portion of a previously formed pile, or

preferably I perform both the building and slicing operations simultaneously. This latter procedure may be carried out by continually advancing the growing pile toward the slicing means, as for example by spreading the fiber upon a slowlymoving table, belt or creeper, and continuing to deposit the material upon thi moving support at substantially the same rate that I remove material in sections from the upright face of the heap. V

In practicing this continuous process it is preferable first to build up a heap of the desired depth or number of layers or lamince before the slicing operation begins, and

of the present process, I contemplate that alternate layers of laminae of the pile or drift above referred to may each consist wholly of nber irom one of said batches, that is LO say, if, as. above suggested, one batch of fiber be red ant the other White, the first layer deposited may be'entirely of red fiber, the second of White, thethird of red, and so on. @n the other hand, when pneumatic means is employed for delivering the fiber to the pile or heap, the fiber from the several batches may si1m1lta.eously be delivered by means, for example, of separate pneumatic conveyors and allowed to settle indiscriminately on the heap. Further, while such pneumatic means, that is, an air current, bearing the fiber in suspension is a desirable agent for depositing the fiber, I contemplate that mechanicalor other means may be employed for the purpose as, for example, a moving belt'upon which the fiber is placed and which is provided with suitable discharge means for distributing the fiber evenly over the desired area.

In the accompanying drawings I have illustrated one. form of apparatus useful in practicing the present process, although I wish it to be understood that the process herein described is not necessarily limited to thisparticular mechanism or apparatus but may be performed by the use of any other appropriate means.

In the accompanying drawings:

Fig. l is a diagrammatic side elevation, partly broken away and partly in section, illustrating the preferred apparatus;

Fig. 2 is a vertical section, partly in elevation, showing the central portion of the apparatus illustrated in Fig. 1, but 10 larger scale;

Fig. 3 is a vertical section, substantially on the line 33 of Fig. 1, but to much larger scale;

Fig. 4 is a fragmentary side elevation of the right-hand portion of the apparatus (as viewed in Fig. 1), but illustrating the opposite side thereof and to larger scale; and v Fig. is a fragmentary vertical section substantially on the line 5-5 of Fig. 1.

In performing the present process I find it convenient to employ an elongate casing 1 which may be constructed of any desired material such, for example, as wood, sheet metal, composition board, or the like, and which provides a large enclosed chamber 2 in which the essential steps of the present process are carried out. The casing l preferably comprises side walls 3 and 3 and the top 4, consisting of panels supported by a suitable framework 5. If desired this casing may have one or more doors as indicated, for example, at 1 to give access to the chamher 2 for inspection of the contents of the chamber or for observation of the operation while going on. Preferably the end 70f the casing 1 is not as high as the opposite end.

For good results I have found that a casing of approximately twenty-five feet in length, five feet in width and varying in height from approximately five feet at one end to about eight feet at the other end is suitable for the purpose. WVhile I have just mentioned certain definite dimensions, it is to be understood that these are merely illustrative of the general proportions of parts which I have found suitable and are not in any way to be regarded as restrictive of the invention.

The casing is preferably supported upon legs 6 or other appropriate means so as to space it a little way above the floor of the workroom, and the high or delivery end of the casing'preferably merges into a metallic end frame of easing 8 adapted to support various shafts hereinafter referred to.

At a point adjacent to the low end 7 of the casing I mount a shaft 9 in suitable bearin gs, such shaft supporting a roller 10 forming a guide and support for one end of an endless conveyor belt or creeper 11 consisting of a flexible base member 13 (Fig. 5) of canvas or other suitable material and a series of transverse slats 12 suitably secured to this canvas base. The upper run of this endless belt 11 constitutes the floor of the chamber 2, such upper run being substantially horizontal. The opposite end of this belt passes around a roller 14 mounted upon a shaft 15 journaled in the end casing 8. The upper run of the belt is preferably supported by means of a series of rollers 16, while the lower run of the belt is also preferably sup ported by rollers 16, the rollers 16 and 16 being journaled in suitable brackets conveniently carried by the legs 6. The upper run of the belt 11 fits snugly against the lower edges of the side walls 3 and 3 of the easing, and if desired suitable packing material such, for example, as a band of soft leather,

canvas,or the like, may be arranged at this point to'prevent the escape of air and fiber from beneath the edges of the casing.

A suitable stand 17' provides journal bearings for a main driveshaft 18 which may carry tight and loose pulleys, (not shown) adapted to receive a drive belt leading to a suitable source of power. The shaft 18 also carries a pulley 19 about which the belt2O passes. This belt 20 engages a pulley upon a shaft 21 extending transversely through the end casing 8' and having secured to its opposite end a sprocket wheel 22 (Fig. 4c). The sprocket wheel'22 is connected, by means of a sprocket chain 28, to a sprocket wheel 24 turning upon a stud shaft 25 mounted upon the casing 8. This sprocket wheel 24 is fixed to a gear 26 meshing with a gear 27 upon a shaft 28 extending tranversely' through the end casing 8. This shaft 28 carries a roller supporting the upper end of an endless spike apron 29. The lower end of this apron passes around [a roller 20 close ly adjacent to the roller 14 and carried by a shaft 31 journaled in the end casing 8 and which drives (by means of suitable speed reducing gearing) the shaft 15 above referred to. As thus arranged the speed of the spike apron 29 is much greater than that of the slat apron or belt 11. As here shown the spike apron 29 extends upw'ardly from the delivery end of the beltll and 'is pref erably somewhat inclined from the vertical and away from the beltor apron 11. However, I may, if desired, arrange-this slat apron so that its active run will be vertical, or I may arrange it to incline in the opposite direction from the vertical, as compared with the arrangement shown herein.

Furthermore, I{ contemplate that certain of the desirableresults attainable by the practiceof my process'may be secured by arranging the spike apronor its equivalent so as to move in a horizontal path transverse to the path of, movement of the belt 11.

The shaft 21 carries adoffer device, not

shown, for removing the fiber from the upper end of the spike apron 29, whereby to deliver it into the mouth of the conveyor pipe 32 which may lead to any desired apparatus in which the fiber is further treated. For example, this pipe maylead to a card ing machine or to a card feeder of usual construction, not herein shown, as it forms no part of the present invention.

At the opposite end of the casing 1 IPYO- vide an inlet conduit 33, preferably inclining upwardly at the point Where it enters the casing. This conduit 33 is of a cross-sectional area very considerably less than that of the casing 1 so that air entering at a given velocity through the conduit 33 loses its velocity very quickly as it passes into the chamber 2. After the air has flowed at relatively slow speed longitudinally ofthe chamber 2, it passes outagain through the pipe I 32 where its velocity increases sufficiently to by hand or by suitable feed mechanism. The,

picker .35 and the feeder 36 are here shown merely as illustrative of means for roughly openingpand mingling the fiber before delivery to the casing l, but the present invenspecific exemplification of the process herein ti-on is not concerned with the particular form of apparatus usedin the preliminary treatment of the fiber, except that, for the illustrated, it is desirable to deliver the fiber into the conduit 33 while in suspension in an air current of high velocity adapted to carry it'through the conduit 33 and to deliver it' into the chamber 2 in the form of a jet.

Asthe air flowing through the conduit 33 enters the chamber 2 it moves in an up -wardly inclined jet or stream, as indicated by the arrows at 38, but as this jet rapidly loses velocity, the fiber which is carried by the jet gradually settles by the action of gravity ina thin layer upon the floor or belt 11 and eventually builds up an elongate heap ordrift 39 consisting of a large num berof superposed layers, strata or lamina. Sinceby reasonfof the momentum of the entering fiber and the draft of air'always moving longitudinallyof the casing, these layers, strata or laminae tend to be thicker atthe right-hand end of the casing (as viewed in Fig. 2) than at the opposite end, and thus the driftusually takes somewhat the form indicated in Fig. 2, thatis to say, it is deepest at the point most remote from the conduit 33, from'which point it'tapers gradually toward the end 7 of the casing, the length of the drift,'under properworking conditions,

preferably being at least twice its maximum depth. This drift, as diagrammatically indicated in Fig. 2, consists of a great number of thin superposed layers or laminae since 1t is evident that at each successive instant in. the operation of the apparatus a certain quantity of fiber settles out of the air onto the previously. accumulated heap or drift,

and thus the material which accumulates during any short interval of time, no matter how short such interval may be taken, may

' be considered as constituting a distinct layer, although such layers usually merge imperceptibly into one another. Since the area of the floor 11 of the chamber is large,

as compared with the quantity of cotton at any instant in suspension above it, it is clear wouldaccumulate to any substantialdcpth at one point upon the floor of the casing.

The spike apron 2 9 constitutes the effective end wall for the chamber 2, at the end remote from the conduit 33, and the drift of fiber builds up against the active or upwardly movable run of this spike apron. After the drift has once been built up to a substantial thickness the spike apron and the belt 11 are started into operation, and it is obvious that the upward movement of the spike apron 29 tends to separate a thin layer of fiber from the end of the pile and to carry such thin layer upwardly to the point where it is dotted from, the spike apron by the dotfer carried on the shaft 21. If the belt,

rial delivered into the casing.

In the continuous course of operation of the mechanism, the spike apron is continuously fed by'the forward movement of the beltll so that as fast as it removes the fiber from the advancing face of theheap, fresh fiber is presented by the movement of belt 11 and the operation is thus uninterruptec It is thus possible to consider that the spike apron removes a continuous slice from the end of the heap, such slice at any instant consisting of portionsof all-of the several layers as above referred to. The slow movement of the belt 11 continues to move the pile or heap bodily toward the spike apron, enabling the latter to bite off portions of the end of the heap at substantially the same rate that the heap is built up by deposit of new layers upon its upper surface, and thus the mixing and'blending operation may be continuedas long as material is furnished to the spike apron. As the rate of the belt is the belt driven at the same rate as the spike apron, a selective removal of fiber of one kind from the heap or mass might be expected. I

Since the fiber is deposited so gently,'it forms a very loose, light and fioceulent heap from which all heavy dirt and dust tends to fall freely onto the belt where it collects in the recesses between the slats and is eventually dumped as the belt passes downwardly about the roller let. Moreover, the low widely extended slowly movingheap, in the presence of the large volume of air moving through the chamber, furnishes ideal condi tions for aeration of they fiber permitting it to bloom, fluff out, and regain its original shape and elasticity. 7

While this method of depositing thematerial pneumatically is very desirable, I contemplate, as above suggested, that the material may be deposited upon the moving floor or belt 11 in other ways than by the use of air. For example, it is conceivable that suitable mechanical means for performing the same operation might wellbe employed, any such, device being cons dered to be the equivalent of the pneumatic means herein specifically illustrated.

While I have illustrated a spike apron 29 as the means for slicing oi the fiber at the end of the heap I wish itto be understood that this is merely illustrative of suitable means for performing this operation since I contemplate that other means might be employed for producing the same result. It is also to be understood that the relative speeds of the spike apron and floor 1 1 are not necessarily such as herein disclosed but that under other circumstancesand in dealing with fiber of other character a different relative speed of these moving parts might Well be found desirable. Moreover, I do not consider that the exact shape of the casing is an essential feature of the invention since I contemplate that desirable results may be obtained with casings of other type and conceivably in the open workroom, although it is evident that the latter arrangement would hardly be practical due to the enormous loss of fiber which would probably occur and the unhealthy conditions of the workroom resulting from the great accumulation of lint and fly in the air.

I claim: 1. That method of mixing textile fibers of a type suitable for spinning which comprises delivering all of the fiber which is to be mixed into air moving at high velocity, discharging said fiber-ladenair in the form of an upwardly inclined jet into a closed space in which the air current loses velocity, permitting the suspended fiber to settle and form an elongate drift, advancingthe drift bodily in alongitudinal direction, and constantly removing the fiber which at any given instant constitutes the advancingend of the drift. 1

2. That method of mixing textile fiber of a kind suitable for spinning which comprises blowing all of the fiber by means of an air current into a closed chamber to form an elongate drift in said chamber, that end of the drift remote from the point .ofentrance of the fiber being higher than the other, moving the drift bodily with: its deeper end in advance, removing vertical sections from its advancing end while continuing to add fiber to. its upper surface.

3. Apparatus for use in mixing textile fiber of a kind suitable for spinning, said apparatus comprising a substantially air-tight hollow casing providing an elongategchanr ber, means for delivering a fiber laden cure,

rent of air at high velocity and of relatively small cross section, as compared with the section of the chamber, into one end of the a chamber, the currentmoving longitudinally of the chamberthe sudden reductioninair velocity of the entering air causing the fiber to be deposited ina drift within the chamber, and means moving transversely of'the direction of the entering air current. for

removing fiber from that side of the'drift remote from the point of entrance of the air current and pneumatic means for \conveying such removed fiber from. the chamber. c

4. .Apparatus for use 'm mixing textile fiber suitable for spinning which comprises an elongate substantially air-tight hollow casing higher at one end than the other, a pneumatic conveyor conduit entering the lower end of the casing, means for delivering fiber-laden air into the casing through said conduit whereby tobuild up a driftofliber, said drift being higher at the high end of the casing than at the opposite end, an upwardly moving spike apron adjacentto the higher end of the casing, the high end of the drift engaging the upwardly moving apron, and means for ;moving the apron ghereby to remove fiber from the "end of the ri t. I I I c 5. Apparatus for'use inmixing textile fiber suitable for spinning comprising'a casing providing an elongate chamber, an endless belt constituting the floor of the chamber, means forblowing'all of the fiber to be drift being highest near such remote end of c the chamberfa spike apron defining the remote end of the drift, and means for moving the spike apron whereby to remove fiber from said end'of the drift, thelinearspeed' of the spike apron being greater than that of the belt.

6. Apparatus for use in mixing textile fiber, suitable forspinning comprising a cas-- providing substantially air-tight elongate chamber, an endless slat apron constitilting the floor,- of the chamber, a conduit leading into anend of the 'chamber, said conduit being inclinedupwardly, meansfor deliveringv a current of fiber-laden air through said conduit into the chamber in an upwardly: inclined jet, the fiber carried by said jet spreading laterally and longitudinally of the chamber and forming a drift upon the slat apron, an upwardly moving spike apron defining that end of the drift c remotefrom the entering air-jet, means for s moving the slat apron slowly toward the spike apron, and meanstor'moving the'latterat a relatively highspeed;

7 That continuous process of treating textile fiber of'a kind suitable for spinning 'positingsaid flocks over a widely extended which, comprises as steps depositing all of the fiber to be treated in widely extended superposed strata to form a heap, advancing said heap bodily while maintaining said strata substantially undisturbed in relative position, and -continuously removing fiber from the advancing layers of the several strata. I

8.-That continuous process of treating textile fibers suitable Y for spinning which comprises separating allot the fiber to be treated into small flocks, continuously dearea to form superposed laminae which are thicker at one end than at the other-and which merge withone another to form a heap which is deepest adjacent to one end, and

removing substantially vertical slices from said deeper end of the heap.

' 9. That continuous process of treating textile fibers suitable for spinning which comprises as steps continuously depositing all of the'fiber to be treated in widely-eX- tended superposed substantially parallel layers to form a heap, and maintaining the layers substantially undisturbed in relative position while continuously removing the fiber constitutingone edge only of each of said layers,

' 10. Thatcontinuous process of treating textile" fiber suitable for spinning which comprises as steps delivering all of'the fiber to be treated in flocculent condition and at high velooityiand in such a direction into c ing'in depth from oneend toward the other, a and, continuously removing substantially one end of an, elongate chamber as to cause the fiber to sweep lengthwise of the chamber--v and form an elongate drift or heap increasvertical sections from the deeper end of the drift.

11.-Thatprocess of mixing textile fiber suitable for spinning which comprises as steps delivering allof the fiber to be mixed at high velocity onto a slowly moving conveyor travelling in the same general; direction as the fiber whereby tobuild up adrift of fiber deepest at its advancing end, and moving a spike apron at high velocity compared with that of the conveyor, along the advancing face of the heap whereby continuously to remove fiber from said faces.

12. That method of cleaning,-mixing and aeratingtextile fiber "suitable for spinning which comprises delivering all of the fiber to be treated in loose flocculent condition into a body of air and'permitting the fiber to settle out of the air upon an endless conveyor having open spaces into which dirt may drop, the fibers forming a loose drift'of greater length than height, moving the conveyor to advance'thedrift bodily, and continuously removing fiber from the entire area of the advancing end of the drift, the speed ofthe conveyor being, so slow as to allow substantial aeration of the fiber with recovery of its normal shape and elasticity before it reaches the spike apron.

13. Apparatus for use in mixing textile fiber of a character suitable for spinning :the delivery end of the casing, a conveyor constituting the eitective floor of the casing,

means for moving 'said'conveyor slowly toward the discharge end of the casing, a spike apron extending upwardly from the delivery end of the conveyor, means for driving the spike apron at a speed substantially greater than that of the conveyor, a doii'er shaft adjacent to the upper end of the spike apron,

and a pipe leading from the upper part of the delivery end ofthe casing, said pipe providing a passage for a fiber conveying'air current.

14:. Apparatus for use in mixing textile fiber of a character suitable for spinning comprising an velongate substantially airtight casing ofa height 'at'its receiving end approximately one-fifth-of its length and of a height at its delivery end approximating one-third of its length, said casing comprising fixed side, top andend walls, a floor for the casingcomprising an endless conveyor belt whose upper run moves in substantially air-tight contact with the side walls of the casing, a spike apron within the casing at its delivery end, said apron extending upwardly from the delivery end of the conveyor belt, an inletconduit entering the receiving end of the casing in an upwardly inclined direction, and a discharge pipe leading fromthe delivery endof the casing. a

15. In combination with a picker device -.for picking textile fiber of. a suitable staple for spinning, a conduitleading from said picker through Which all of the fiber to be treated is conveyed by an air current, an elongate casing into which said conduit delivers its fiber-laden air current, said casing comprising top and side Walls defining a chamber in which the velocity of the air current decreases and wherein the fiber settles in an elongate drift, a delivery conduit extending from that end of the cham- 10 her opposite to that at which the fiber enters, and means for removing portions of the fiber from the drift and feeding itinto'said delivery conduit.

Signed by me at Esm'ond, Rhode Island 15 this 1st day of April 1927.

DEXTER STEVENS.

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