US3807950A

US3807950A - Method of dyeing and/or washing fabric

Info

Publication number: US3807950A
Application number: US00188736A
Authority: US
Inventors: R Rogers
Original assignee: Individual
Current assignee: Individual
Priority date: 1971-10-13
Filing date: 1971-10-13
Publication date: 1974-04-30
Anticipated expiration: 1991-04-30

Abstract

A process is disclosed for continuously washing and/or dyeing a moist web of fabric as the web of fabric passes through a steam chamber in which a plurality of drums define a path of travel therethrough for the web of fabric. Steam is introduced into the chamber to provide a humid atmosphere therein and heat the fabric and at least some of the drums are heated to a temperature above the ambient temperature to apply heat directly to the fabric raising it above the temperature obtainable by use of a steam chamber alone. Additional heat is introduced into the chamber by heated panels mounted adjacent to the path of travel of the fabric between adjacent rollers which serves to maintain the temperature of the fabric as it passes from one heated drum to the next. The path of travel of the fabric passes through at least one trough which may contain water or other cleaning fluids therein to wash the fabric at elevated temperatures. The cleaning fluid is also sprayed onto the fabric as it moves along its path to aid in the washing operation.

Description

United States Patent 1191 Rogers 1 Apr. 30, 1974 [76] Inventor: Robert Kenneth Rogers, 4109 Laurel Dr., Raleigh, NC. 27612 22 Filed: Oct. 13,1971

21 Appl.No.: 188,736

[52 US. Cl 8/175, 8/73, 8/l49.1, 8/149.3, 8/176, 8/D1G. 16, 68/5 1), 68/5 E 511 1111. C1 D06p 5/02 [58] Field of Search 34/41, 119; 8/14, DIG. l6, 8/l49.l, 149.3; 68/5 D, 5 E

[56] References Cited UNITED STATES PATENTS 3,728,076 4/1973 vFleissner 8/149.1 3,632,301 1/1972 Meier-Windhorst 8/176 3,401,412 9/1968 Meier-Windhorst 68/5 E 3,396,415 5/1968 Meier-Windhorst 8/149.3 2,516,199 7/1950 Fry 34/119 3,619,103 11/1971 Williams et a1. 8/14 3,401,745 9/1968 Pato et a1 165/90 2,413,567 12/1946 Hornbosted 34/124 OTHER PUBLICATIONS Kern, R., Modern Continuous Dyeing Processes 15 May 1961, American Dyestuff Reporter pp. 45-52.

Primary ExaminerGeorge F. Lesmes Assistant Examiner-William R. Dixon, Jr.

[57] ABSTRACT A process is disclosed for continuously washing and/or dyeing a moist web of fabric as the web of fabric passes through a steam chamber in which a plurality of drums define a path of travel therethrough for the web of fabric. Steam is introduced into the chamber to provide a humid atmosphere therein and heat the fabric and at least some of the drums are heated to a temperature above the ambient temperature to apply heat directly to the fabric raising it above the temperature obtainable by use of a steam chamber alone. Additional heat is introduced into the chamber by heated panels mounted adjacent to the path of travel of the fabric between adjacent rollers which serves to maintain the temperature of the fabric as it passes from one heated drum to the next. The path of travel of the fabric passes through at least one trough which may contain water or other cleaning fluids therein to wash the fabric at elevated temperatures. The cleaning fluid is also sprayed onto the fabric as it moves along its path to aid in the washing operation.

7 Claims, 1 Drawing Figure MTENTEDAPRSOlBY 3.807.950

INVENTOR. ROBERT KENNETH BY ROGERS LERNER, DAVID & LITTENBERG METHOD or DYEING AND/R WASHING FABRIC FIELD OF THE INVENTION This invention relates to a process for dyeing and/or washing a web of fabric.

BACKGROUND OF THE INVENTION Fabric has been dyed and the dyed fabric washed for thousands of years. New fabrics have of course been continuously introduced during the years, including synthetic fabrics. As each new fabric is developed, the dyeing and washing characteristics thereof must be taken into account to determine which of the prior art processes are most suitable thereto or if, in fact, new procedures must be developed. Notwithstanding the longhistory of the fabric dyeing and washing industry, optimum techniques have not yet been developed.

Perhaps the most common method employed for dyeing fabrics are the batch processes in which a quantity of fabric isimmersed in an aqueous solution of a dye. The dye normally is heated to a temperature in the range of about 260 F. The fabric is left therein for a period of time typically an hour or more. There are two interrelated reasons why such a long time interval at such a relatively low temperature is required. First the dye because it is in an aqueous solution is not sufficiently concentrated to dye the fabric at a high rate of speed. Secondly the fabric can withstand high temperatures for only short intervals of time. Therefore, since a long interval of time is required due to the low concentration of dye, the temperatures obtainable must be lowered to protect the fabric again extending the time interval to complete the dyeing process.

The use of the lower temperature complicates the dyeing process further by introducing Barree patterns in the material. The Barree patterns are determined by and due to the previous history of the fibers in the fabric during manufacture thereof and tension developed in the fibers during knitting of the fabric. It has been found that dyeing at higher temperatures can minimize the sensitivity of the material to temperature variation with respect to the Barree problem but the period of dyeing in an aqueous solution will not allow this.

A further drawback of the above process is that the fabric being dyed occupies the processing equipment for an extended period of time. Thus, if a sufficiently fast continuous dyeing process were developed, the active floor space of the dyeing facility could be more economically utilized.

To overcome these problems, a continuous dry dyeing process was developed. This process involves the application of a paste-like concentrated dye to the fabric and then passing of the fabric through a heated area (at approximately 425 F.) for a short interval of time. The heat is normally supplied by open gas flames. This process tends to minimize the Barree problem but results in a low quality relatively stiff fabric due with poor hand" due to the dry heat. The fact that gas flames are necessary to produce the desired heat precludes the possibility of maintaining a sufficiently humid environment.

Various attempts have been made to overcome this problem by passing a fabric having a concentrated dye coating thereon through a steam chamber to provide a rapid continuous moist dyeing process which produces a high quality fabric. In such a continuous process, the fabric must pass into and out of a dyeing chamber which can, therefore, not be sealed. It has been found that the temperature of a dyeing chamber cannot be raised above approximately 220 F. by the introduction of steam therein without pressurization. As a result, it appears that the prior attempts at continuous moist dyeing in steam chambers have been abandoned.

BRIEF DESCRIPTIONOF THE INVENTION The present invention overcomes the above and other problems by providing a process for continuously moist dyeing a web of fabric which includes the steps of applying a concentrated dye to the surface of the fabric and then heating the fabric to a temperature of above 220 F. in a humid atmosphere. The process takes place in a processing chamber formed in a machine through which the web of fabric is passed. A plurality of drums are mounted in the chamber to define a path of travel for the web of fabric. Steam is introduced into the chamber to heat the chamber to an ambient temperature of about 220 F. to supply the additional heat to the fabric. Still further, heated panel members or panels are disposed adjacent the path of the fabric at at least some of those portions between heated drums to maintain the temperature of the fabric above 220 F. and preferably above 300 F.

A cleaning trough, also included in the machine, is used for holding a reservoir of fluid through which the fabric passes on its path of travel. Cleaning fluid may also be sprayed onto the fabric adjacent to the trough. A second trough is included in the machine and spans the exit opening from the chamber to provide a fluid seal for preventing steam from leaking out of the chamber and also for aiding in washing of the fabric.

It has been found that the washing of the fabric after dyeing at the elevated. temperatures is sufficiently advantageous over previous washing methods that according to this invention fabric is washed by the steps of heating the fabric to a temperature of approximately 220 F. in a humid atmosphere and while maintaining the fabric under tension immersing it in a clean fluid.

DESCRIPTION OF THE DRAWINGS The sole FIGURE is a sectional side view of a machine for processing a web of fabric in accordance with the teachings of this invention.

DETAILED DESCRIPTION OF THE INVENTION Referring now to the sole FIGURE of this invention wesee a machine 10 having a chamber 11 formed therein. A web of fabric 12 passes through a path in the machine defined by rollers 13 through 22. The web of fabric 12 enters the chamber through a conventional entry port 23 and exits therefrom through an exit opening 24. i

The drums 13 through 19 are heated drums which may have steam or heated oil therein. The drum 13 may be heated to, for example, a temperature of between 220 to 250 F. The drum 14 may be heated to, for example, a temperature between 250 and 300 F. The drum 15 may be heated to, for example, a temperature between 300 and 350 F. while the drums 16 and 17 may be heated to the'same temperature of between 350 and 500 F. The drums l8 and 19 may be maintained at a temperature of about 200 F.

The drum 20 is perforated and has spray

nozzles

26 and 27 therein to spray a cleaning fluid such as water on the web of fabric 12 as it passes therearound.

Spray pipes

28, 29 and 31 may spray cleaning fluid on the outside of the fabric as it passes around the

drums

19, and 21 respectively. The

drums

20 and 21 are perforated. A plurality of perforated steam pipes 32 through 34 introduce steam into the chamber 11 in the area of the drums 13 through 17.

A plurality of panels 35 through 39 heated to a temperature of, for example, about 500 F extend from the walls of the chamber 11 between the web of fabric 12 as it passes between the drums 15, l6, 17, 18 and 19 to aid in maintaining the temperature of the fabric above the ambient temperature available with steam alone as it passes between the drums.

The steam introduced through the perforated steam pipes 32 through 34 may be superheated to a temperature of in excess of 400 F. However, the equilibrium temperature in the chamber due to the introduction of the superheated steam is typically in the range of 220 F. The heat supplied to the fabric directly from the drums enable the fabric 12 to be heated above the temperatures normally obtainable in non-pressurized steam chambers. As noted previously, the heat supplied by the panels 35 through 39 help maintain the fabric 12 at the elevated temperatures as it passes between the respective drums.

A trough 41 is located in the chamber 11 partially surrounding the drum 18. A second trough 42 partially surrounds the drum 22 and spans the exit opening 24.

in operation the web of fabric 12 is passed between a pair of concentrated

dye applying pads

43 and 44 so that the web of fabric 12 is coated on both sides with the concentrated dye as it enters the chamber 11 through the conventional entry port 23. If for example the fabric 12 is textured polyester, the concentrated dye applied to the web of fabric 12 can comprise a dispersed dye in a dispersing agent, a carrier to help swell the fiber, and gum and acetic acid to control the pH during dyeing.

As the coated web of fabric 12 enters the entry port 23 it passes between

heated pipes

46 and 47 and under heated pipe 50 which help prevent condensation and dripping of the steam onto the fabric. The chamber 23 is also subject to suction via a suction pipe to help evacuate the chamber 23 thereby preventing excess steam build up and dripping.

As the web of fabric 12 passes over the

rollers

13, 14 and 15 the temperature thereof builds up through a combination of the exposure to the steam environment and the heat directly applied from the drums. It will be noted in this embodiment that the temperature of the drums progress from the temperature of the steam environment to the ultimate dye fixing temperature arrived at at the drum 16. This is done since alternate sides of the fabric pass over alternate drums which could result in facing of the material if dye fixation occurred rapidly on one side.

After the fabric 12 passes over the last dye fixing drum 17 it is immersed in a washing fluid in the trough 41. A chemical feed member 48 is provided to introduce cleansing or pH fixing fluids into the trough. It will be noted that drum 18 is at a lower temperature than the dye fixing drums but yet is still at an elevated temperature so that the still hot fabric 12 can be more easily washed. The fabric 12 moves from the drum 18 to the drum 19 where it is sprayed from the pipe 28 on the right hand side. It should be noted that a baffle 49 is interspersed between the fabric coming to and leaving the drum 19. This is done so that dirty water dripping off the fabric after it leaves the trough 41 will fall back towards the trough 41 rather than onto the fabric further down the line.

After leaving the drum 19 the fabric 12 moves onto the drum 20 where it is sprayed on both sides by the perforated pipe 29 and the spary heads 26 and 27. The fabric 12 then is passed over perforated drum 21 for further spraying from the pipe 31. It should again be noted that a baffle 51 is provided to insure that whatever water drips therefrom is fed back rather than forward onto the cleaner fabric. The fabric 12 then passes around the drum 21 through trough 22 which is filled above the exit opening 24 so that the cloth in its final washing operation inside the chamber 11 passes out of the chamber 11 through a liquid barrier which helps maintain the steam in the chamber 11.

After leaving the chamber 11 the web of fabric 12 is passed over a vacuum slot 52 to draw off moisture. The fabric 12 is then passed through normal processing and dye fixing baths before being wound on a bolt or folded.

It has been found that the dyeing of fabric in this manner allows high quality dyeing to be achieved in as little as a 2-minute interval. it has also been found that the washing of the fabric in the steam chamber at the elevated temperatures produces more efficient washing than was heretofore available. To this end the machine 10 may be employed even without the heated drums to wash webs of fabric. The fact that the web of fabric is held in open width on the roller during the raising and lowering of the temperature under humid and moist conditions prevents wrinkling thereof due to thermal shock.

It should of course, be understood that the drums 13 through 22 are driven to move the fabric through the chamber 12. Conventional differential drums could be used to account for stretching of the web of fabric 12 as it passes through the machine.

Access doors

53 and 54 are provided one on each side of'chamber 11 (only one of each such door being shown). Access door 53 comprises a window 56 and access door 54 comprises window 57 for inspection purposes. It will be appreciated that these doors can be opened or removed enabling one to work within chamber 11.

The baffles may be pivotally and/or removably mounted as desired to aid in the maintenance of the machine and in the treating of a web of fabric therein. In this regard, the drums may also be removably mounted.

it should be understood that other classes of dyes may be used in combination or separate from the disperse dyes cationic, acid, etc.

It should be understood that while this invention has been described with respect to the specific embodiment thereof, numerous others will become obvious to those of ordinary skill in the art in light thereof.

What is claimed is:

1. A process for continuously moist dyeing a web of fabric including the steps of:

applying a concentrated dye to the surface of said fabric;

heating said fabric to a temperature within the range of from about 200 to about 250 F;

then heating said fabric to a temperature varying in a dispersed dye in a dispersing agent;

the range of from about 300 to about 500 F; and a carrier to help swell the fiber of the fabric;

a gum; and cooling said fabric to a temperature of about 200 F acetic acid.

or below. 5 5. The process in accordance with claim 1 wherein 2. The process as defined in claim 1 in which heat is said fabric is heated in an environment saturated with supplied by direct contact to said fabric. steam.

3. The process as defined in claim 1 in which said 6. The process as defined in claim 1 including the web of fabric is moving along a path and heat is supstep of applying cleaning fluid to said fabric during or plied to said fabric by direct contact to said fabric at 10 after said cooling step. preselect spaced positions on said path. 7. The process as defined in claim 6 wherein said 4. The process as defined in claim 3 in which said cleaning fluid is water. concentrated dye includes:

Claims

2. The process as defined in claim 1 in which heat is supplied by direct contact to said fabric.
3. The process as defined in claim 1 in which said web of fabric is moving along a path and heat is supplied to said fabric by direct contact to said fabric at preselect spaced positions on said path.
4. The process as defined in claim 3 in which said concentrated dye includes: a dispersed dye in a dispersing agent; a carrier to help swell the fiber of the fabric; a gum; and acetic acid.
5. The process in accordance with claim 1 wherein said fabric is heated in an environment saturated with steam.
6. The process as defined in claim 1 including the step of applying cleaning fluid to said fabric during or after said cooling step.
7. The process as defined in claim 6 wherein said cleaning fluid is water.