US3218654A - Method for continuous mottletreatment of yarns - Google Patents

Description

Nov. 23, 1965 SHIRO YANO ETAL 3,218,654

METHOD FOR CONTINUOUS MOTTLE-TREATMENT OF YARNS Filed NOV. 5, 1962 3 Sheets-Sheet l INVEN 'ro R S SH/EO YANO E/ZAB URO KA WA RA BA YA SH! 5740/ CH/ 774Kl/EA 7/! K07! MOEOKA WA BY M ATTO R N EY Nov. 23, 1965 SHIRO YANO ETAL 3,218,654

METHOD FOR CONTINUOUS MOTTLE-TREATMENT OF YARNS Filed Nov. 5, 1962 3 Sheets-Sheet 2 N v E N TO R S HIIPO y/l N0 572/? ewe/4 KA WA /&4 BA VA 5/-// JHO/CH/ 771 KU/EA M UJ7 NOIPOKA WA ATTO R N EY Nov. 23, 1965 sumo YANO ETAL 3,218,654

METHOD FOR CONTINUOUS MOTTLE-TREATMENT OF YARNS Filed Nov. 5, 1962 3 Sheets-Sheet 3 N v E N TO 2 s SH/RO YA NO 5/ ZABU/QO KA WA reA 6A YASH/ 3/. '0/ CH/ TAKU/QA 774 KUJ'I flo/eoA A WA ATTORNEY ite tts 3,218,654 METHOD FOR CONTIWUGUS MOTTLE- TREATMENT OF YARN Shiro Yano, Misasagi, Yamashina, Higashiyarna-ku,

Kyoto, Eizaburo Kawarabayashi, Kitashirakawa, Sakyol-ru, Kyoto, Shoichi Takura, Shiehihonmatsudori, Kamilryo-kn, Kyoto, and Takuii Morokawa, Ulryo-ku, Kyoto, Japan, assignors to Toyo Rayon Kabushiki Kaisha, Tokyo, .lapan, a corporation of Japan, and Eizaburo Kawarahayashi, Shoichi Talmra, and Takuji Morokawa, all of Kyoto, Japan Filed Nov. 5, 1962, Ser. No. 235,262 Claims priority, application .llapan, Nov. 10, 1961, 36/40590 1 Claim. (Cl. 8-1512) This invention relates to a method for continuous mottle-treatment of yarns. More particularly, it relates to a method for continuous mottle-treatrnent of yarns in the longitudinal direction thereof which is characterized by imparting vibration to a running yarn by means of a vibrator whereby the yarn is caused to intermittently con tact a yarn treating means.

Heretofore, methods of mottle-dyeing yarns have including sprinkle dyeing, board dyeing, fasten dyeing, etc. In sprinkle dyeing, yarns are put in a skein, a dye liquor is sprinkled over the skein of yarns in small drops and thus mottle-dyeing is effected. In board dyeing, yarns are made into a bundle, placed between boards and pressed tight therewith, and immersed in a dye liquor. The parts of the yarns placed between boards are protected from dyeing and thus mottle-dyeing is effected. Fasten dyeing is a method heretofore widely practiced in the production of cloths with splashed patterns. The yarns are made into a bundle, fastened with a string or the like at the locations not to be dyed, then immersed in a dye liquor, whereby the fastened parts remain undyed in mottles.

In the methods mentioned above, although the outer part of a yarn bundle may produce desired mottles comparatively accurately, it is extremely difiicult to control with assurance the mottles produced inside the bundles. Also, such methods have so far been practiced only by handicraft and a great amount of labor and a high level of experience are necessary for the practice of these methods. Further, in the case of weaving or knitting textiles from mottle-dyed yarns, since the weaving or knitting is performed with the patterns being adjusted by hand, the process is very inefficient and the reproducibility is extremely poor.

Commercial methods of mottle-printing of yarns, which have been proposed include a method of adhering a dye liquor to the yarn by means of an engraved roller and a method wherein a nozzle for supplying a dye liquor is moved up and down so as to come into an intermittent contact with a yarn which is running. However, in the former, each desired pattern requires a different roller. In the latter, in case a high density of spotty distribution is desired, that is, a pitch of untreated part of a yarn in the longitudinal direction is desired to be small, the running speed of the yarn would have to be made extremely low. Thus, with these methods it is diflicult to meet the demand for a wide range of spotty patterns unless productivity is sacrificed.

It is the principal object of this invention to provide a commercial method for treating yarns at constant intervals as desired along the longitudinal direction of the yarn or thread.

Another object of the invention is to provide a process for continuous mottle-treatment of yarns in the longitudinal direction thereof which facilitates the control of the length and distribution of 21 treated part and an untreated part in a wide range.

3,218,654 Patented Nov. 23, 1965 A particular object of this invention is to provide a commercial method for dyeing a yarn at desired constant intervals along the longitudinal direction of the yarn or thread.

Another object of the invention is to provide a commercial method for releasing crimps of crimped woolly yarns at desired constant intervals along the longitudinal direction of the yarn.

Still another object of the invention is to provide a commercial method of applying pastes or adhesives to a yarn with desired constant intervals along the longitudinal direction of the yarn.

Other objects and advantages of the invention will become apparent from the following description and the appended claim.

The above-described objects of the invention are attained by the following process which comprises continuously running a yarn, and imparting vibration to said running yarn by means of a vibrator, thereby causing the yarn to come into intermittent contact with a yarn treating means which is provided within the scope of the amplitude of the vibration of the yarn.

The present invention will be explained with reference to the accompanying drawings.

FIGURE 1 is to explain the principles of the invention. A yarn 1 previously wound up on 2 is continuously taken up on 3. 6 and 7 are, respectively, a tension controller and supporting rolls provided along the running di rection of yarn 1 so as to impart a constant tension to the yarn and regulate the length of vibration of the same. Between 6 and 7 a vibrator 4 is provided to impart to the yarnvibration having a constant period and amplitude. 5 is a yarn treating means disposed within the amplitude ocfi of the yarn. Yarn 1 contacts said yarn treating means 5 intermittently, once in a given period, and thus the yarn can be treated accurately in constant lengths at regular intervals. In case the yarn is desired to be dried before being wound, 7 may be made a drying means.

Any suitable method for the continuous running of a yarn may be employed in the process of this invention. For example, a yarn may be run by taking up the same from a package via one or more guide rollers.

In general, when a vibration is imparted to a fixed yarn, the resulting vibration period is peculiar to said yarn. In the present invention, however, since a yarn is continuously running, vibration is given to said yarn only when it passes through a certain section of small length. The energy necessary for said vibration is continuously imparted by means of a vibrator, and the period of vibration is determined by that of a force vibration, namely, the period of a vibrator. Accordingly, by the proper selection of a vibrator, the number of mottles per unit length of a yarn may be freely and accurately determined. Additionally, by varying the running speed (winding speed) of a yarn, tension of a yarn, the length of a section within which a yarn is vibrated and the length of contact of a yarn with a treating device, the length of mottles and intervals may be freely adjusted.

There are no limitations regarding the kinds of vibrating devices to be used in this invention. Mechanical methods, electrical methods, magnetic methods, etc., may be properly selected according to the particular needs. Any means for transmitting vibration to a yarn, either by direct contact or indirect contact with a vibrator, may be used. In the case of indirect contact a resonance box may be placed between the yarn and the vibrator.

On of the methods for imparting vibration to a yarn by a vibrator shown in FIG. 2, wherein a pillar having angles, such as a triangular pillar or a pillar having bars, is used and said pillar is rotated at a high speed, whereby a running yarn is made to contact the angled edge of the pillar. When a rotated angled-pillar 21 comes to a position 21', yarn 22 which is in contact with said pillar comes to position 22' and is imparted an amplitude oz. The running yarn is vibrated at a frequency which varies with the rotary speed of said angled-pillar and at an amplltude which corresponds to the shape and size of the angled pillar. Said frequency and amplitude may properly be selected in accordance with the running speed of a yarn. In case an angled pillar, particularly a triangular pillar, is used, one of the combinations of the yarn speed, rotary speed of the pillar, frequency of vibration of the yarn and the number of mottles obtained therefrom is given below as an example:

Wind-up speed of yarn 250-300 m./min. Number of revolutions of triangular pillar 3000-6000/m1n Frequency of vibration of yarn 9,00018,000/m1n. Number of mottles 30-72/m.

In another embodiment of this invention, as shown in FIG. 3a, 3b, a vibrating plate is used. Namely, one end of a vibrating plate 32 is fixed and the other end thereof is made to come into intimate contact with the teeth of a gear 31 as said gear rotates. By rotating gear 31, vibration is imparted to a vibrating plate 32 which transmits said vibration to a running yarn 33. The running yarn is imparted vibration in accordance with the frequency and amplitude of said vibrating plate. An example of the combination of the yarn speed, the number of revolutions of the gear, the number of teeth of the gear, the frequency of vibration of the yarn and the number of mottles per meter, in case the gear as described above is used, is given in the following:

Wind-up speed of yarn 250-300 m./min. Number of revolutions of gear 3,0006,000/rnin. Number of gear teeth -15. Frequency of vibration of yarn 15,000-90,000/m1n. Number of mottles 50-360/m.

In another embodiment of this invention as shown in FIG. 4, a magnet is used to directly vibrate a yarn. The operation of this embodiment is like the vibration of a horn of a speaker in a radio. An electro-magnet 42, as a trembler to a permanent magnet 41, is connected to a resonance box 43 and a running yarn 44 is contacted therewith. By properly charging intermittent electric current to electro-magnet 42, said electro-magnet vibrates and such vibration is transmitted to a running yarn via said resonance box. A yarn treating device such as, for example, a nozzle for supplying a treating liquor is disposed in such a manner that the proper part of the running yarn thus vibrated may intermittently contact said nozzle.

In another example embodying the present invention, as shown in FIG. 5, an electro-magnet 51 is provided with a light-weight permanent magnet 52, which is connected to a resonance box 53. By contacting a running yarn 54 with said resonance box and applying intermittent electric current to said electro-magnet, vibration may be transmitted to said yarn. In this case, a resonance box is not necessarily employed, as a running yarn may be contacted with a permanent magnet.

In still another embodiment of this invention, as shown in FIG. 6, an electro-magnet 61 and an electro-magnet 62 are oppositely disposed. Between magnets 61 and 62, a light-weight permanent magnet 63 which is capable of vibrating is positioned. Magnet 63 may be connected, if necessary, with a resonance box (not shown). By contacting a running yarn 64 with said permanent magnet and applying proper intermittent electric current to said electro-magnet, said permanent magnet is caused to vibrate, thereby transmitting vibration to said yarn. In this method, since the permanent magnet is vibratably disposed between two electro-magnets, by making the amplitude of said permanent magnet great, the amplitude of the vibration of said running yarn may be made great.

In another modification of this invention, as shown in FIG. 7, a multi-pole disc 71, alternately provided with N and S poles around the periphery thereof, is rotated at a high speed. A vibrating plate 72, one end of which is fixed, is disposed towards the periphery of said disc, but not in contact with the disc. By vibrating said vibrating plate, the vibration may be transmitted to a running yarn 73. A multi-pole disc may be a light-Weight permanent magnet or an electro-magnet. As a vibrating plate, an iron plate or a metal plate charged with magnetism, or a plastic plate furnished with a permanent magnet at the end thereof, may be employed.

In still another exmaple, vibration may be imparted to a running yarn by means of friction or other means and oppositely providing thereto an electrode which periodically converts positive and negative static electricity in alternation.

Yarn treating devices which may be used in this invention include a nozzle and a roller to supply necessary treating liquors for the desired treatments such as, for example, dyeing, padding or crimp releasing. As a device for releasing crimp a heating roller may also be employed. These yarn treating devices should be disposed within the limit of amplitude of a yarn. The position of the yarn treating device is, is most cases, preferably close to a trembler, for the amplitude of vibration of a yarn is comparatively large. However, a yarn treating device may be located at any position, provided that the amplitude of vibration of a yarn is appropriate at said position. A treating liquor to be fed to a nozzle may be supplied by means of a pump. If desired, the amount of a treating liquor to be supplied from a pump may be periodically varied.

No special limitation is imposed on treating liquids usable in this invention. The treating liquids may be those which can be used in the usual yarn treatment such as dyeing liquors, resist printing liquors, dye pastes, resin liquors, swelling agents and the like.

The yarns which can 'be treated according to the method of this invention may be natural fibers such as cotton, wool and silk, artificial cellulose fibers such as viscose rayon, bemberg rayon and acetate, synthetic fibers such as polyamide and polyester, or spun yarns or continuous filament yarns comprising the mixtures thereof. Also, yarns may be crimped beforehand.

In the dyeing a yarn with mottles according to the method of this invention, a dye liquor suitable for the fiber being treated may be utilized. However, in the case of synthetic fibers, i.e., polyamide fiber, polyester fiber, polyacrylonitrile fiber and polyolefin fiber, generally their dyeability is unsatisfactory. Since in accordance with the method of the present invention the dyeing time is short, where deep shades are desired, it is necessary that a dye liquor of especially good dyeability be used. Examples of such a dye liquor include dispersed dyes or oil dyes in which a swelling agent or solvent has been blended. Further, the conventional carrier may also be blended in these dye liquors. The dispersed dyes and oil dyes as used herein are those dyes which possess practically no hydrophilic groups and are water-insoluble.

The swelling agents or solvents used are substances which are capable of swelling fibers, for example, phenol, formic acid and calcium chloride-methanol for the polyamide fibers; chlorobenzene, benzene alcohol, and ethane tetrachloride for the polyester fibers; benzene and carbon tetrachloride for the polyolefin fibers; and zinc chloridemethyl alcohol, phenol and metacresol for the polyacrylonitrile fibers; etc.

As the carriers, there are the conventionally employed surfactants, polyethylene oxide and the like. In addition, salts may also be added.

The dyeing method to be used in the invention is not limited to the dyeing method which employs a dye liquor in which has been blended a swelling agent. It is also possible to use the dyeing method which uses a dye having a hydrophilic group, or the azoic dyeing method which employs a coupling component and an azotizing component. Since it is desirable for the dye liquor to adhere to the yarn without flowing, it is preferable that viscidlty be imparted to the yarn. As dye liquors possessing viscidity, those that are of the same class as print dyes are suitable. According to the method of the invention, after the dye liquor has been caused to adhere to the yarn, it is fixed to the yarn by heating with a heater. Steps consisting of washing with water and drying may also be provided subsequent to the heating step. ThlS washing step may however be performed separately.

After adhering the treating liquid to the yarn in accordance with the mottling treatment of the present invention, the treating liquid is caused to act on the yarn by means of heating at a suitable temperature. While this temperature is not critical, it is desired that the treating liquid that has adhered to the yarn in a mottled fashion be heated at a temperature requisite to render thorough coaction between the yarn and the dyeing liquor.

This heating may be accomplished by employment of a heating wheel, or a heated tube may be used through which the yarn is made to pass. Alternatively, infrared heating may be utilized, or blowing of hot air may be employed. This heating is carried out at a temperature ranging between room temperature and the melting temperature of the fiber.

In order to more clearly understand the present invention, the following specific examples are given, it being understood that the examples and drawings given herein are merely intended in an illustrative sense, and the invention should not be limited thereby, and that changes may be made therein without departing from the scope of invention which is defined in the appended claim.

Example 1 As shown in FIG. 8, a yarn was run from a package 81 through a guide roller 82. Tension was imparted to said running yarn by means of a tension apparatus 83 and vibration was imparted thereto by way of rotating a triangle-pillar cam 84 which is in contact with said yarn. The top end 85 of a nozzle for supplying a treating liquid was made to intermittently contact said yarn. The yarn thus spottily treated was heat dried upon a wheel heater 86 and thereafter wound up via a guide roller 87.

The yarn used for the above treatment was a crimped nylon yarn of 110 x 2 ply. The treating liquor used consists of 1000 cc. of methanol, 100 g. of calcium chloride, and 20 g. of waste nylon yarn which has been boiled in a flask provided with a condenser for 15 minutes thereby completely dissolving and thereafter cooled. Said treating liquor was supplied to a nozzle by means of a pump. The nozzle used had a width of 0.5 mm. and length of 20 mm. at the end thereof. The rotary speed of the triangle pillar cam was 3000 r.p.m., the surface temperature of said wheel heater, around which said yarn was once wound, was l60l70 C., and the wind-up speed of said yarn was 180 m./min.

In accordance with the above example, a novel intermittently crimped yarn wherein a crimped part and a crimp-released part interchangeably appear in the longitudinal direction thereof was obtained.

Example 2 This specific example relates to a method of spotty dyeing of a nylon filament yarn. As shown in FIG. 9, a yarn was run from a package 91 by means of a guide roller 92. Tension was imparted to said running yarn by means of a tension device 93. Vibration was imported to said yarn by contacting said running yarn with a vibrating plate 95 to be vibrated by means of a gear 94. The top end 96 of a nozzle for supplying a dye liquor was intermittently contacted with said yarn, and

the thus obtained yarn dyed in mottles was heat dried upon a wheel heater and thereafter the yarn was wound up by means of a guide roller 98.

The yarn used for treatment in this example was a nylon filament yarn of 110 As the dye liquor, a mixture obtained by dissolving 10 g. of Neolan Black WAN (Ciba Co.) in 100 cc. of water, heating the same for 10 min. at C., and after completely cooling, admixing cc. of 2% aqueous solution of CMC and 3 g. of ammonium acetate by stirring was used. Said dye liquor was supplied to a nozzle by means of a pump. The nozzle used therein had a width of 0.5 mm. and a length of 20 mm. at the top end thereof. A ratchet wheel of nylon having ten teeth was employed. By rotating the same at a speed of 7,200 r.p.m., vibration was generated to a vibrating plate of nylon having a thickness of 0.5 mm. Around a wheel heater, whose surface temperature was 170 C., the treated yarn was wound up at a speed of m./min.

The pitch of dyed mottles and the number of mottles per cm. in the above case are as follows.

Wind-up speed 180 m./min.

Revolutions of ratchet wheel 7,200 r.p.m.

take-up speed ratchet Wheel revolutions X 10 The treatment in this example was performed so that a dyed part and a non-dyed part appeared in a ratio of 1:1, therefore Pitch of mottles:

Example 3 In this example, a magnetic vibrator of 500 cycles was used. An extremely fine piano wire connected with said magnetic vibrator was disposed at a right angle to the longitudinal direction of the yarn and thereby vibration was transmitted to said yarn. As a yarn treating device, a roller having a diameter of 1 cm. was used. By rotating said roller at a speed of ISO/min. in the same direction as the yarn, running and disposing the same at a height in the vicinity of the center of the amplitude of said yarn, a dye paste was intermittently adhered to the yarn. The yarn used was 70 deniers and was wound up at a speed of 500 m./min. As a result, a treated yarn wherein a mottle and an interval between mottles, respectively 5 mm. in length, was obtained.

In the above example, another roller to feed a dye paste of another color was additionally provided and the distance between the two rollers was properly adjusted. As a result, mottles of two colors were continuously obtained in a single step. By varying the distance between the two rollers, those mottles wherein one mottle is partially superposed upon the other were also obtained.

Furthermore, by additionally providing a vibrator comprising a triangle-pillar cam, driven by means of a motor of 3000 rpm. and vibrating said yarn in a vertical motion of about 5 mm., a yarn was treated so that the mottles therein were in a complex and non-uniform arrangement, but repeated with constant regularity.

Number of mottles per cm.=l X 4 7 Example 4 In this example, a magnetic vibrator of 500 cycles was used as a vibrating means and an electrothermic wire of 300 W enveloped in a quartz pipe was used as a yarn treating device. The yarn used for treatment was a crimped nylon yarn of 110 x 2 ply and taken up at a speed of 300 m./min. Consequently, an intermittently crimped yarn wherein the length of a crimped part and that of a crimp-released part were respectively 1 cm. in the natural unstretched state thereof was obtained. The product obtained in this example possesses a crimped part and an uncrimped part with an equal interval. If the point of heating is adjusted to contact the yarn for a shorter period of time, an intermittently crimped yarn wherein the crimped parts are more closely connected may be obtained.

The yarns imparted with the eifects of mottle-treatments as in the above examples may be used as they are. However, With additional treatments applied to said spottily treated yarn, a yarn may be further treated as desired. For example, when an untwisted yarn is treated with a thick paste in mottles in accordance with the present invention, thus making mono-filaments gathered at mottles, dried and thereafter twisted, the parts of the yarn not treated with the paste remain substantially untwisted. Thus, a yarn wherein a twisted part and non-twisted part interchangeably appear may be obtained. After weaving or knitting said yarn into a fabric, the paste is removed by dissolution and thereby a three-dimensional effect may be attained in the fabric due to the irregularity of stress between the twisted part and the non-twisted part. Furthermore, by the spotty application of adhesives to a yarn '8 followed bythe adhesion of other substances to said treated parts, other desired effects may be obtained.

What is claimed is:

A method for the mettle-treatment of yarns which comprises contacting a continuously running yarn with a vibrating means thereby effecting vibration of said yarn, said vibrating means actuated by a vibratable magnet located between a pair of electro-magnets oppositely disposed yarn, said electro-magnets being vibrated by means of vibrating electric current applied thereto; contacting the vibrating yarn intermittently along its length with a yarn treating device, said yarn treating device being located at a point longitudinally separated from said vibrating means and being within the range of amplitude of said vibrating yarn; adhering a liquid from said yarn treating device at points intermittently along the length of said vibrating yarn and then heating said yarn.

References Cited by the Examiner UNITED STATES PATENTS 1,175,538 3/1916 Matos 68-205 X 1,240,625 9/ 1917 Taylor.

1,532,559 4/1925 Thomayer 68-203 X 1,575,234 3/1926 Thomayer 68-203 X 1,651,167 11/1927 Van Alstyne 68-203 X 1,992,259 2/1935 Taylor 68-203 X 2,247,716 7/ 1941 Schellenberg.

2,694,307 11/1954 Henry 68-3 X IRVING BUNEVICH, Primary Examiner.

WALTER A. SCHEEL, Examiner.

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