US3916040A - Process for manufacturing flock - Google Patents

Process for manufacturing flock Download PDF

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Publication number
US3916040A
US3916040A US437617*A US43761774A US3916040A US 3916040 A US3916040 A US 3916040A US 43761774 A US43761774 A US 43761774A US 3916040 A US3916040 A US 3916040A
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US
United States
Prior art keywords
tow
fibers
flock
finish
scouring
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US437617*A
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English (en)
Inventor
Winston E Hagborg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Westpoint Pepperell Inc
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Westpoint Pepperell Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Westpoint Pepperell Inc filed Critical Westpoint Pepperell Inc
Priority to US437617*A priority Critical patent/US3916040A/en
Priority to CA211,705A priority patent/CA1028485A/en
Priority to DE19742450520 priority patent/DE2450520A1/de
Priority to GB4667574A priority patent/GB1438746A/en
Priority to NL7414160A priority patent/NL7414160A/xx
Priority to BE151453A priority patent/BE823289A/xx
Priority to JP49146337A priority patent/JPS50107259A/ja
Priority to IT47853/75A priority patent/IT1026473B/it
Application granted granted Critical
Publication of US3916040A publication Critical patent/US3916040A/en
Assigned to BANKERS TRUST COMPANY reassignment BANKERS TRUST COMPANY LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: WEST POINT-PEPPERELL, INC.
Anticipated expiration legal-status Critical
Assigned to WEST POINT-PEPPERELL, INC. reassignment WEST POINT-PEPPERELL, INC. RELEASE OF SECURITY INTEREST & ASSIGNMENT Assignors: BANKERS TRUST COMPANY
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G99/00—Subject matter not provided for in other groups of this subclass

Definitions

  • the present invention relates to a process for manufacturing flock for use in textile applications. Typical uses for flock are described in US. Pat. No. 3,528,874 to Francis T. Spencer. Briefly, the Spencer patent discloses an arrangement wherein flock is deposited on an adhesive coated substrate, the adhesive securing the flock to the substrate. The resultant product is suitable for use as blankets, sleeping garments, upholstery fabrics, draperies, etc.
  • flock be free of any finish which would impair its lustre, hand and abi1- ity to be deposited on the substrate.
  • the flock be devoid of clusters or calls so as to insure uni form distribution.
  • flock fibers should be straight rather than curled.
  • the present invention constitutes an improved process for manu facturing flock which prevents curling and fusion of the flock and provides the flock with a finish which is compatible with the method by which it is deposited. Briefly, this is accomplished by passing the tow through a scouring bath to remove the finish applied to the tow material during manufacture. While in a wet state, the tow is directed through a cutter which chops the tow into fibers of the desired length. Thereafter, the fibers are dried and are placed in storage. Either prior to the cutting step or after cutting the material is subjected to a finishing operation in which suitable chemicals are applied to ready the flock for its ultimate use.
  • l is an illustration of the scouring and finishing portions of the flock manufacturing process according to a preferred embodiment of the invention.
  • FIG. 2 is an illustration of the cutting, drying and storing portions of the flock manufacturing process, according to a preferred embodiment of the invention
  • FlG. 3 is an enlarged view, partially fragmented, of the cycione separator shown in H6. 2;
  • FIG. 41 is a block diagram illustrating an alternative process for flock manufacturing according to the invention.
  • FIG. 5 is a block diagram of a further alternative process for flock manufacturing according to the invention.
  • HG. e is a side elevational view, partially in section, illustrating equipment suitable for use in the extraction step diagrammatically shown in FIG. 5.
  • a tow of filaments designated as 10, is drawn from a supply bin. While this tow is preferably of synthetic material, such as nylon, polyester, rayon or an acrylic, it is also contemplated that the tow may be formed of natural fibers.
  • the tow 11h as it is removed from the supply bin, contains a finish imparted during its manufacture having properties which are undesirable for the intended application of the flock. Typically, these properties are cohesive and anti-static characteristics which contribute to clustering of the flock fibers and difficulty in depositing the flock when an electrostatic process is employed, such as is described in US. Pat. No. 3,528,874 Spencer. Consequently, such a deleterious finish must be removed.
  • This is done by passing the tow 10 through a tensioning arrangement, comprising an eye 12 and conventional spreader bars 14, to a tank assembly generally indicated at 16.
  • the spreader bars are a conventional combination of curved and straight bars which prepare the tow for the scouring operation by flattening It.
  • the tank assembly 16 comprises four tank sections 18, 20, 22 and 24. Each of the sections is provided with a conventional multiple roller arrangement to permit several changes in direction of the two as it passes through the section. Additionally, a drive roller 26 is provided at the output end of each tank section to draw the tow therethrough. A guide roller 28 is positioned at the input end of tank 18. An assembly of squeeze rollers 30 is mounted on a suitable framework 32 to permit the rollers 30 to be selectively withdrawn from corresponding rollers 26 or advanced into cooperative relationship therewith.
  • the squeeze rollers 30 are dropped to engage the tow thereby permitting the drive rollers 26 to carry the tow through the several tank sections 18, 20, 22 and 24 and deposit it in a receptacle 34.
  • the scouring agent is a combination of soap, a suitable solvent and soda ash maintained at an elevated temperature of approximately lF.
  • the tow moves to tank section 20 where it is exposed to a first rinse, and from tank 20 the tow passes to tank section 22 for further rinsing. While only two rinses are disclosed, it will be understood that any number is appropriate provided the original finish and the scouring agent is removed from the tow by the time it exits from the last rinse.
  • the details of the rinse operation need not be presented here inasmuch as they are well known. However, it should be mentioned that the temperature of the rinses correspond substantially to that of the scouring bath.
  • the tow 10 On exiting from tank section 22, the tow 10 passes into tank 24 where a new finish is applied to the tow.
  • This finish is of a character which enhances the ability of the tow material, when chopped into flock fibers,to flow or sift. In other words, the finish is one which minimizes the tendency of the flock to cluster. Additionally, the finish is made compatible with the adhesive which is ultimately utilized in securing the flock to a substrate. If the flock is to be electrostatically deposited, the electrical properties of the finish are selected to facilitate such a step.
  • a typical finish agent having the foregoing properties consists of Leomin KP Type F and waterglass.
  • Leomin KP Type F is a quaternary fatty acid derivative marketed by the American l-loechst Corporation located in Mt.
  • the temperature of the bath is elevated. Typically, this temperature is in the order of 140 F.
  • the arrangement is such that the collected tow which is deposited in receptacle 34 is in a substantially wet state, e.g., 0.3 to 0.4 pounds liquid per pound of dry tow.
  • a plurality of receptacles 34 (not shown in FIG. 2), each filled with a wet tow 10, are arranged adjacent a conventional creel assembly 36 only one stage of which is shown.
  • the combined tows from the several receptacles 34 are directed through the creel assembly to a cutter unit 38.
  • the unit shown is a conventional commercially available guillotine type cutter having a puller roll incorporated therein. While a guillotine type cutter is disclosed, it is apparent that other types of cutters, such as rotary ones, may be employed. Additionally, supplemental pull rolls linked to the cutters roll may be interposed between the cutter 38 and the creel assembly 36.
  • the pull rolls move the combined tow bundle from the creel assembly 36 by indexed amounts (e.g., 2 mm) past the cutter knife.
  • cutter 38 operates at a rate of approximately 120 cuts per minute. Inasmuch as the tow is wet as it passes the knife, the latter is maintained in a cool condition so as to inhibit fusing of the flock fibers which otherwise would occur if the tow were dry so as to 'allow the knife to increase in temperature during the cutting operation.
  • the flock fibers drop via a chute 40 into a duct 42 which is positioned intermediate a heater 44 and a blower 46.
  • the direction of movement of the fibers as they enter duct 42 is approximately at right angles to the longitudinal axis of the duct.
  • the fibers and heated air from heater 44 are pneumatically moved by blower 46 through ducts 42 and 48 to a mechanical separator, such as a conventional pin mill 50.
  • the blower also assists in separating lumps of fibers.
  • the flock is flash dried, the ducts being thermally insulated to facilitate such drying.
  • the drying process is controlled by a thermally responsive element 52 which is positioned in duct 48 just upstream of the pin mill 50.
  • the temperature responsive element 52 is operatively connected to a valve arrangement (not shown) positioned within duct 42 between the heater 46 and chute 40.
  • the valve is continuously adjusted to control the temperature within the duct to a value of approximately 300 F. This reduces the moisture content of the flock fibers to a sufficient level to prevent clustering.
  • the length of the ductwork is selected to facilitate the drying operation.
  • the purpose of the pin mill 50 is to assist in breaking up clusters of fibers which are formed for example by the knife in the cutter 38 dulling or developing nicks so as to cause light fusion of the flock fibers.
  • the fibers exiting the mill 50 are directed via an additional insulated duct 53 to a conventional cyclone separator 54 which isolates the dried flock fibers from the heated air, the latter being exhausted to atmosphere.
  • the cyclone separator 54 is shown partially fragmented in FIG. 3. It can be seen that as the heated air carrying the flock fibers enters the separator, it swirls in the chambers within the separator established between the inner cylindrical wall 56 and the separators outer wall. Centrifugal force separates the heavier flock fibers from the air stream, the conical base 58 below cylinder 56 facilitating the direction of the air upwardly to be exhausted to atmosphere while the dried fibers drop through a funnel 60 to a collection drum 62 (FIG. 2).
  • FIG. 4 One such variation is illustrated in FIG. 4.
  • the finishing step between scouring and placing the wet tow through the creel is eliminated in favor of a finishing procedure subsequent to the dried flock fibers being passed through the pin mill.
  • the fibers are dried completely in the flash drying step, and as the fibers pass through duct 53, a conventional nozzle arrangement introduces a fine mist of finishing materials of the type previously described to the air stream to coat the fibers. By suitable adjustment of the nozzle, the moisture content of the resultant flock can be controlled to acceptable limits.
  • FIG. 5 again eliminates the finishing step between the scouring and cutting steps.
  • the wet tow is cut, it is combined with a liquid to form a slurry.
  • the flock fibers are suspended in unclustered condition in the liquid permitting suitable finishing materials to be added to the slurry so as to coat the fibers.
  • the slurry is next directed to screening devices to drain the bulk of the liquid from the mixture.
  • the remaining wet mass of fibers is then introduced to conventional dewatering apparatus, such as a pressure or centrifugal extractor, or to continuously operating equipment such as that disclosed in FIG. 6.
  • the wet mass is placed in the hopper and is carried by a motor driven auger 64 from a feed section to a compression chamber 66 which separates additional liquid from the fibers.
  • the moist fibers then are carried through a metering section by the auger and are introduced to a duct 42' corresponding to duct 42 in the embodiment of FIG. 2.
  • Duct 42' is connected between a heater and a blower in a manner similar to the FIG. 2 arrangement so as to flash dry the fibers to a desired moisture level.
  • the dried fibe'rs are subsequently directed to a cyclone separator to be processed as previously described.
  • a process of manufacturing flock from a tow of textile material comprising the steps of:

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Preliminary Treatment Of Fibers (AREA)
US437617*A 1974-01-29 1974-01-29 Process for manufacturing flock Expired - Lifetime US3916040A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US437617*A US3916040A (en) 1974-01-29 1974-01-29 Process for manufacturing flock
CA211,705A CA1028485A (en) 1974-01-29 1974-10-18 Process and apparatus for manufacturing flock
DE19742450520 DE2450520A1 (de) 1974-01-29 1974-10-24 Verfahren und vorrichtung zur herstellung von faserflocken
GB4667574A GB1438746A (en) 1974-01-29 1974-10-29 Process and apparatus for manufacturing flock
NL7414160A NL7414160A (nl) 1974-01-29 1974-10-30 Werkwijze en inrichting voor het vervaardigen van vlokken.
BE151453A BE823289A (fr) 1974-01-29 1974-12-12 Procede et appareil pour fabriquer des flocons
JP49146337A JPS50107259A (xx) 1974-01-29 1974-12-21
IT47853/75A IT1026473B (it) 1974-01-29 1975-01-27 Apparecchio e procedimento per la fabbricazione di fiocchi tessili

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US437617*A US3916040A (en) 1974-01-29 1974-01-29 Process for manufacturing flock

Publications (1)

Publication Number Publication Date
US3916040A true US3916040A (en) 1975-10-28

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ID=23737177

Family Applications (1)

Application Number Title Priority Date Filing Date
US437617*A Expired - Lifetime US3916040A (en) 1974-01-29 1974-01-29 Process for manufacturing flock

Country Status (8)

Country Link
US (1) US3916040A (xx)
JP (1) JPS50107259A (xx)
BE (1) BE823289A (xx)
CA (1) CA1028485A (xx)
DE (1) DE2450520A1 (xx)
GB (1) GB1438746A (xx)
IT (1) IT1026473B (xx)
NL (1) NL7414160A (xx)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2609475A1 (fr) * 1987-01-09 1988-07-15 Isolindustrie France Machine a carder des fibres, notamment des fibres de laine minerale, comprenant une tremie pourvue d'un organe rotatif de cardage et de decoupe de fibres
WO2012136141A1 (zh) * 2011-04-08 2012-10-11 福建海源自动化机械股份有限公司 连续精确计量的连续纤维定长切断方法和装置
CN108035016A (zh) * 2018-01-09 2018-05-15 浙江伊森爱家纺有限公司 一种梳棉机的棉料打散装置
CN113819747A (zh) * 2021-10-11 2021-12-21 深圳市金绒达新材料科技有限公司 一种基于服装生产的植物纤维烘干装置

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5075022A (en) * 1988-02-24 1991-12-24 Monsanto Company Heat transfer fluids

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3490938A (en) * 1966-12-20 1970-01-20 Calgon C0Rp Electroconductive flock
US3714136A (en) * 1971-10-21 1973-01-30 American Cyanamid Co Process for recovering acrylamide polymers from gels

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3490938A (en) * 1966-12-20 1970-01-20 Calgon C0Rp Electroconductive flock
US3714136A (en) * 1971-10-21 1973-01-30 American Cyanamid Co Process for recovering acrylamide polymers from gels

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2609475A1 (fr) * 1987-01-09 1988-07-15 Isolindustrie France Machine a carder des fibres, notamment des fibres de laine minerale, comprenant une tremie pourvue d'un organe rotatif de cardage et de decoupe de fibres
EP0277438A1 (fr) * 1987-01-09 1988-08-10 Isolindustrie France Machine à carder des fibres, notamment des fibres de laine minérale, comprenant une trémie pourvue d'un organe rotatif de cardage et de découpe des fibres disposé coaxialement au système d'alimentation mais à sens de rotation inverse
WO2012136141A1 (zh) * 2011-04-08 2012-10-11 福建海源自动化机械股份有限公司 连续精确计量的连续纤维定长切断方法和装置
CN108035016A (zh) * 2018-01-09 2018-05-15 浙江伊森爱家纺有限公司 一种梳棉机的棉料打散装置
CN108035016B (zh) * 2018-01-09 2019-04-30 浙江伊森爱家纺有限公司 一种梳棉机的棉料打散装置
CN113819747A (zh) * 2021-10-11 2021-12-21 深圳市金绒达新材料科技有限公司 一种基于服装生产的植物纤维烘干装置

Also Published As

Publication number Publication date
IT1026473B (it) 1978-09-20
CA1028485A (en) 1978-03-28
NL7414160A (nl) 1975-07-31
JPS50107259A (xx) 1975-08-23
DE2450520A1 (de) 1975-07-31
BE823289A (fr) 1975-04-01
GB1438746A (en) 1976-06-09

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AS Assignment

Owner name: BANKERS TRUST COMPANY, NEW YORK

Free format text: LICENSE;ASSIGNOR:WEST POINT-PEPPERELL, INC.;REEL/FRAME:005270/0552

Effective date: 19891023

AS Assignment

Owner name: WEST POINT-PEPPERELL, INC., GEORGIA

Free format text: RELEASE OF SECURITY INTEREST & ASSIGNMENT;ASSIGNOR:BANKERS TRUST COMPANY;REEL/FRAME:007074/0442

Effective date: 19931210