WO2020202667A1

WO2020202667A1 - Method for manufacturing cotton-containing product

Info

Publication number: WO2020202667A1
Application number: PCT/JP2019/050296
Authority: WO
Inventors: 宮本　博; 基久野間; 正敬大島
Original assignee: 一般社団法人Ｈ．Ｍ．Ｃ．; 株式会社ナゴヤ大島機械
Priority date: 2019-03-29
Filing date: 2019-12-23
Publication date: 2020-10-08

Abstract

In manufacturing a cotton-containing product, scouring and bleaching are performed on a cotton material in the form of a sliver.

Description

Manufacturing method of cotton-containing products

The present invention relates to a method for producing a cotton-containing product.

In recent years, cotton agriculture has been developed and rationalized in terms of cultivation methods, seed improvement, research and development, and attempts have been made to expand production. The basic material of the cotton produced is fiber made of cellulose, but it has a brownish color instead of white because it contains primary impurities such as dirt and a small amount of oil that adhere to the plant before harvesting. ing. If these impurities are contained, even if an attempt is made to dye a cotton product, the impurities will repel the dye and it is difficult to dye as expected.

For this reason, in the processing of fibers containing cotton, it is necessary to remove the above impurities, make them white, and then dye them. Specifically, knitted fabrics and woven fabrics are manufactured using spun raw yarn, and scouring and bleaching is performed at a dyeing factory equipped with wastewater treatment equipment and a water supply environment to make a pre-sewing machine.

Specifically, the spun yarn is scoured and bleached with a package dyeing machine or a Hank dyeing machine as a "skein shape" for dyeing, and the spun yarn is scoured and bleached with a package dyeing machine for dyeing as a "cheese shape". Is commonly done. In some cases, in order to reduce costs, scouring and bleaching may be performed with a package dyeing machine, and dyeing may be performed with a Hank dyeing machine.

In addition, when dyeing yarn for jeans, a rope dyeing machine is often used to bundle the yarn. However, for scouring and bleaching, a package dyeing machine is often used because of the thread shape.

For example, Patent Document 1 proposes a processing method for removing cotton cloth by scouring and bleaching, including secondary impurities added in the spinning, spinning, weaving, and knitting processes. Further, Patent Document 2 proposes a chemical treatment method for removing glue and scouring a woven fabric. Further, a method of scouring and bleaching the raw yarn at the yarn stage and then knitting and weaving to make a pre-sewing raw machine may be used.

JP-A-2002-238555 Japanese Patent No. 5554172

However, this scouring and bleaching process consumes a large amount of water resources. It consumes a large amount of water resources including the dyeing process to be required to manufacture cotton products, but the water resources used for scouring and bleaching are the total water resources used to manufacture cotton products. , 70-80%. Due to the consumption of this enormous amount of water resources, there are many countries and regions that can produce cotton but cannot produce cotton products in their own country. This was one of the major reasons for the cotton textile industry to move from many developed cotton industries to other developing countries.

However, in developing countries, the purification of water resources used was often inadequate, and the production of cotton products sometimes deteriorated the environment in developing countries.

Therefore, the purpose of this invention is to control the water resources consumed in the production of cotton-containing products, and to protect the environment of each country and, by extension, the world.

The present invention solved the above problems by scouring and bleaching a cotton material in a sliver state.

A sliver is an aggregate of strip-shaped or rope-shaped fibers before twisting cotton into yarn. In this sliver state, the individual fibers are separated without being entangled as compared with the twisted yarn, so that the chemicals and water used for scouring and bleaching easily permeate the individual fibers. As a result, water consumption can be significantly reduced as compared with the conventional method of scouring and bleaching twisted yarns and woven fabrics.

Further, in the present invention, it is possible to adopt a configuration in which steam is used to heat the sliver when scouring and bleaching. In the sliver state, since the individual fibers are exposed to the atmosphere, unlike twisted yarns and woven fabrics, adjacent fibers do not interfere with each other, and water vapor easily hits the individual fibers. Therefore, after soaking in the chemicals used for scouring and bleaching, heating by steam proceeds to a high temperature so that the action of the chemicals can be fully exerted by proceeding without being hindered by the adjacent fibers. Can be easily done. Further, since water vapor has a significantly smaller specific gravity than liquid water, it is possible to significantly reduce the consumption as a water resource as compared with the case of heating in a hot water bath for scouring and bleaching. In addition, compared to the conventional method that required a large amount of hot water to be heated for bathing, the mass can be significantly reduced compared to the volume by treating it as steam, so the energy consumption required for heating can also be reduced. ..

Further, in the present invention, when steam is applied to the sliver, it is possible to adopt a configuration in which the slivers are arranged in a sheet shape for scouring and bleaching. The sliver has not been twisted yet, but if it is put together in a rod shape, it may be difficult for water vapor to hit the center. On the other hand, when the slivers are arranged in a sheet shape, all the fibers constituting the sliver are exposed, and the amount of water vapor consumed and the amount of heat required for that can be saved. Further, when the fibers are formed into a sheet, a slight friction is generated between the adjacent fibers, and when the fibers are wet with a chemical solution, water vapor or the like, the treatment can be proceeded while being sequentially transported as a series of sliver sheets.

Further, in the present invention, it is possible to adopt a configuration in which the sliver sheet is washed with water while being transported by a perforated transport medium after being heated by applying the steam. Unlike threads, slivers are not twisted, so if they are pulled strongly in the length direction, they tend to separate, and it is difficult to pull and transport them like threads. Therefore, by placing it on a perforated transport medium and washing it with water, it is possible to transport the sliver sheet constituting the sliver sheet with almost no force and wash it with water. Examples of the transportation medium include a net-like conveyor.

Further, as the perforated transport medium, a net-like inner conveyor and an outer conveyor are used.
Immerse the perforated drum in a washing liquid and arrange it.
The inner conveyor is arranged inside the sliver sheet, and the outer conveyor is arranged outside the sliver sheet.
With the sliver sheet sandwiched between the inner conveyor and the outer conveyor, the sliver sheet is conveyed along the outer periphery of the perforated drum, and the washing liquid inside the perforated drum is sucked to suck the sliver sheet to the outside. A configuration can be adopted in which the sliver sheet is washed with water by passing the washing liquid from the outside of the conveyor in this order through the outer conveyor, the sliver sheet, the inner conveyor, and the perforated drum.

By rotating the sliver sheet along the circumference of the perforated drum while sandwiching it between the perforated transport media, the sliver sheet is washed with water so as to pass through the virtual sheet surface of the sliver sheet without applying a force to separate the sliver sheet. By passing the liquid through, it is possible to wash with water in a small space. Furthermore, by sucking the washing liquid inside the perforated drum to create a negative pressure, the washing liquid is washed from the outside of the net-like conveyor sandwiching the sliver sheet that is rotated along the outer circumference of the perforated drum. Can be washed with water while generating a constant water flow. By circulating a part of the sucked washing liquid to the outside of the net-like conveyor in the water tank for storing the perforated drum, the consumption of the washing liquid can be suppressed. In the conventional general water washing method, water washing is performed by water replacement by bending or lifting in the water washing tank, and the water washing efficiency depends on the number of times of bending or lifting and the number of washing machines. However, this requires a large number of washing machines, and in sliver processing, the bending / lifting process may cause the sliver to run out. It is a suction type, and by sandwiching it with a transport medium and washing it with water while transporting the sliver sheet, the risk of the sliver running out can be further suppressed. Further, although the conventional water washing method requires a large number of long water washing machines, the space required for the water tank is significantly shortened because the water washing machine is arranged along the perforated drum. As a result, water consumption and factory land can be significantly reduced as compared with the conventional case.

Further, after finishing the bleaching, it is possible to adopt a configuration in which the function is added in the state of the sliver. When adding functions to fibers with various chemicals, it is advantageous to add functions in a sliver state in terms of permeation of chemicals and progress of heating, and water resources are compared with cases where functions are added in a hot water bath. It is possible to reduce the consumption of. Since the cotton sliver that has been neutralized and washed with hot water after bleaching is close to pure cellulose, it is highly reactive in imparting functions and has high work efficiency.

The sliver that has been bleached by the above method is sufficiently white in the state of the sliver. By spinning this, a yarn in which the individual fibers are sufficiently whitened can be obtained. With conventional yarns that are twisted and then scoured and bleached, the effect of scouring and bleaching is difficult to reach to the inner part due to twisting, and scouring and bleaching using a large amount of water is required. , The part where bleaching was incomplete was likely to remain. According to the present invention, the yarn obtained by finishing the scouring and bleaching in the state of a sliver is processed into individual fibers because the scouring and bleaching are finished while avoiding the demerits of twisting. It is well fulfilled and of good quality.

Since the sliver of the material containing bleached and refined cotton according to the present invention has already been bleached and refined in the state of the sliver, subsequent dyeing can be easily performed. Further, since the scouring has already been completed, it is possible to easily obtain a textile product through various processes such as spinning, spinning, and woven fabric. At this time, since scouring and bleaching, which consume a large amount of water resources, have already been completed in the state of a sliver, the amount of water resources required to produce cotton products can be greatly reduced. Not only can a yarn spun using the above sliver be used for a 100% cotton cotton product, but also a cotton-containing product obtained by mixing the yarn with a fiber yarn other than cotton can be obtained.

As an apparatus for processing a sliver according to the present invention to produce a cotton-containing product,
A perforated drum immersed in a washing liquid and
A suction device that sucks the washing liquid from the inside of the perforated drum,
A pair of mesh inner and outer conveyors that sandwich the sliver sheet,
The inner conveyor is arranged inside the sliver sheet, the outer conveyor is arranged outside the sliver sheet, and the sliver sheet is sandwiched between the inner conveyor and the outer conveyor along the outer circumference of the perforated drum. It has a conveyor guide device for transporting the sliver sheet.
When the suction device sucks the washing liquid inside the perforated drum, the washing liquid is passed through the outer conveyor, the sliver sheet, the inner conveyor, and the perforated drum in this order from the outside of the outer conveyor. A suction type water washing machine for washing the sliver sheet with water can be adopted.

That is, the production line for producing the cotton-containing product according to the present invention is a production line in which a scouring process and a bleaching process are continuously performed on the cotton material.
For at least one of the scouring step and the bleaching step
Adopted a configuration having a steamer for immersing the sliver sheet made of cotton material and immersing the sliver sheet with steam to heat the sliver sheet, and a suction type water washing machine for washing the sliver sheet after heating with water. can do.

According to this invention, the amount of water resources required to produce cotton-containing products can be significantly reduced, the environmental load can be reduced, and the area where cotton products can be produced can be expanded.

In the conventional batch-type scouring bleaching performed on the yarn after spinning, the scouring process is carried out in a scouring solution such as a surfactant, an enzyme agent, or an alkaline agent for about 30 minutes, and then in the same bath. A bleaching step was carried out with a surfactant, caustic soda, hydrogen peroxide and the like for 60 to 90 minutes. In scouring bleaching using caustic soda, a lot of water and strong neutralizing acid (sulfuric acid) are required to wash and neutralize this high alkalinity, which increases the wastewater load due to the increase in the amount of processed wastewater and the deterioration of the treated water quality. Also, the strong acid caused damage to the equipment. It is not necessary to use strong alkali for continuous bleaching of slivers, the bleaching reaction can be completed in about 3 to 8 minutes, and the scouring reaction can be completed in 5 minutes or less, which is excellent in terms of time reduction. The method. Furthermore, the amount of energy required for heating water can be reduced, and the factory space required for processing can be reduced. Due to these effects, it will be possible to establish a textile factory with a small environmental impact and start the textile industry even in areas where it was difficult to install in the past.

The flow chart which shows the outline of the procedure of the manufacturing method of the cotton-containing product which concerns on this invention. Top view showing an example of the apparatus used for manufacturing the cotton-containing product which concerns on this invention. Front view of FIG. 2A Left side view of FIG. 2A Top view of the water washing machine used in the embodiment of the present invention Front view of FIG. 3A Left side view of FIG. 3A Front enlarged view of the water washing machine used in the embodiment of the present invention Schematic of the suction flush machine used in the embodiment of the present invention. Embodiment photograph of the sliver sheet placed on the stainless net The flow chart which outlines the procedure of another manufacturing method of the cotton-containing product which concerns on this invention.

Hereinafter, the present invention will be described in detail.
The present invention is a method for producing a cotton-containing product using a cotton material, and a cotton-containing product produced thereby. Here, the cotton-containing product includes both a pure cotton product and a product containing cotton and also containing other fibers. In particular, the present invention is suitable for pure cotton products.

The cotton material used in the present invention is a fiber containing cotton. Not only 100% cotton material but also blended fiber of cotton and other fibers can be used. Specific examples thereof include cotton / hemp blended materials obtained by blending hemp and cotton such as ramie (ramie), linen (flax), and hemp (cannabis). In addition, a cotton / wool blend material in which wool and cotton are blended, a cotton / cashmere blend material in which cashmere and cotton are blended, and a cotton / animal hair blend material in which animal hair and cotton are blended are also included. Further, a cotton / silk blend material obtained by blending silk thread and cotton can also be mentioned. Furthermore, cotton / regenerated cellulose fiber blended material obtained by blending regenerated cellulose fibers such as lyocell such as Tencel (registered trademark), cupra (cuprammonium rayon), polynosic, rayon, and bamboo rayon with cotton can also be mentioned. Furthermore, a cotton / synthetic fiber blend material of acetate fiber, nylon fiber, acrylic fiber or other synthetic fiber and cotton can be mentioned.

In this invention, processing is performed in the state of a sliver, which is an aggregate of fibers, before twisting a cotton material into a yarn. It is scoured to remove stains and oils and fats contained in cotton, and bleached to turn a brownish color into white. Basically, after the scouring, the bleaching is performed. Since the fibers of the sliver are not entangled with each other as they are, they will be unraveled if a strong force is applied. Therefore, it is desirable that the processing into a sliver performed in the present invention is performed while transporting with a perforated transport medium. Examples of the perforated transport medium include an aggregate of nets and chains, and a medium having holes in the plate surface. If it is a net, the mesh part becomes a hole. In the case of a chain conveyor in which chains are connected in a plane, holes in individual rings and gaps between rings are holes. Examples of the plate with holes include those with holes on the plate surface of each block constituting the conveyor. Further, there is also a case in which a hole is formed in the peripheral surface of a tubular plate constituting a cylindrical drum.

In the present invention, the sliver is placed on these transport media for processing. Only one type of these transport media may be used, a plurality of transport media may be used alternately, or a sliver may be sandwiched between a plurality of transport media. When mounting on a transportation medium, it is advisable to arrange the slivers in a sheet shape. Slivers arranged in a sheet shape are called sliver sheets. By arranging them in a sheet shape, the fibers that make up the sliver can be treated as a group due to friction between the fibers, and the strength required for transportation and processing is exhibited. As a result, even if the fibers are subjected to water vapor or water flow, which will be described later, it is possible to prevent the individual fibers from separating and separating.

FIG. 1 shows a flow including a production line in which the above cotton material is processed with a sliver to obtain a cotton-containing product. The cotton-containing product is a product made of fibers containing cotton, similar to the above-mentioned cotton material. It includes not only 100% cotton materials but also blended fiber products of cotton and other fibers. Examples of the product form include spun yarn, cloth manufactured from the yarn, clothes and towels manufactured using the cloth, and other practical products. In FIG. 1, a process until a yarn is obtained as a product is shown as an example.

First, the sliver is taken out from the supply source 11 and arranged in a sheet to form a sliver sheet. It is desirable from the viewpoint of work efficiency that the sliver sheet is formed continuously without division. The sliver sheets formed side by side are sequentially placed on the transport medium, and the scouring step 12 is performed. In the scouring step 12, contaminants such as leaves and stems of the raw cotton, oils and fats, impurities and other excess substances are removed before the next bleaching step 13. The sliver sheet that has completed the scouring step 12 is sequentially introduced into the bleaching step 13 as it is. In the bleaching step 13, the yellow or brown-looking color component mainly derived from the original color of the cotton is removed to make the fibers white. After the bleaching step 13, a necessary post-step 14 is performed as appropriate to obtain a bleached sliver in which scouring and bleaching are thoroughly performed on individual fibers. Through the spinning step 15 of spinning the bleached sliver, a yarn which is a cotton product is obtained.

The source of the above sliver may be the Kens method or the wrap winding type. In addition, the production of slivers is obtained by aligning and bundling raw cotton cotton with a card machine. What is bundled in a string shape may be unfolded in a sheet shape later, or may be unfolded in a sheet shape from the beginning. A series of sliver sheets are sequentially formed by arranging continuous sliver-shaped fiber bundles of cotton material into a sheet developed within the width of the transport medium in the machine width used in the subsequent steps. The continuous sliver sheet, which is a series of sequentially formed sliver sheets, is sequentially processed. In order to assist this transportation, it is necessary that the molding speed for molding the continuous sliver sheet and the processing speed for the subsequent steps are the same, or the molding speed is faster. However, since it is necessary to pull the sliver or the sliver sheet until it is placed on the transport medium, it is necessary to adjust the tensile load so that the sliver does not fray.

An example of a production line in which the above scouring step 12 to the post-step 14 are continuously performed on a continuous sliver sheet is a plan view of FIG. 2A, a front view of FIG. 2B, and a side view of the scouring padder 21 of FIG. 2C. Shown in the figure. The process proceeds sequentially from left to right in FIGS. 2A and 2B.

First, the scouring process 12 will be described. The scouring padder 21 performs an immersion step 12a, which is a preparation for the scouring step 12. The scouring padder 21 has a structure for receiving the continuous sliver sheet 51 made into a sheet by the inwardly inclined receiving seat on the lower side of the inlet, and feeds it into the scouring liquid immersion portion 21a. When feeding and transporting inside the device, a transport medium such as a net-like conveyor that can carry a continuous sliver sheet 51 on it is used. It has a structure in which a continuous sliver sheet to which the smelting liquid is applied in the smelting liquid immersion portion 21a is squeezed by a pressure mangle device 21b and then sent out. The temperature of the immersion step 12a does not need to be particularly heated and can be carried out at room temperature (room temperature). The scouring liquid is stored in the scouring liquid dipping portion 21a, and the continuous sliver sheet 51 is immersed in the scouring liquid at a speed of about 5 m / min or more and 10 m / min or less. However, in the general thread scouring process, about 4 to 5 scouring liquid tanks are prepared and continuously passed through the liquid tank to penetrate into the fiber, or a long time with a high temperature chemical solution. It will be processed. This is also because the cotton fibers are covered with fats and oils and pectic substances, so that they are in a water-repellent state that does not absorb water. On the other hand, in the present invention, since the scouring liquid is immersed in the continuous sliver sheet 51, the force of entanglement of the individual fibers is weak, and even in a water-repellent state, the scouring liquid is sufficiently immersed in the individual fibers. Can be distributed to.

The above refining liquid is weakly acidic. It is preferable that the pH is about 3.0 or more and 5.5 or less. It is desirable that the refining solution contains an acid-resistant penetrant, an enzyme catalyst, a degassing penetrant, and the like in addition to the acid component. The enzyme catalyst is an agent that exerts an effect for scouring under the high temperature condition of the next steam heating step 12b. In addition, the degassing penetrant promotes the replacement of the air contained in the sliver with the refining liquid. Since the permeation proceeds rapidly by this degassing penetrant, equipment such as a pre-flushing tank and a chemical attachment tank becomes unnecessary, and the amount of water required for processing can be reduced.

The roll drawing condition of the pressure mangle device 21b on the outlet side of the immersion step 12a is preferably about 70 to 100%. However, a certain degree of wetness is ensured. The continuous sliver sheet in a wet state exhibits strength enough to maintain its shape even in the subsequent processing due to the friction of individual fibers. It is preferable to transport by the above transport medium until just before being sandwiched between the upper and lower rolls, and immediately after squeezing with the roll, transport again by the above transport medium.

Next, the scouring steamer 22 performs a steam heating step 12b for heating the continuous sliver sheet 51 to which the scouring liquid is attached. The scouring reaction is allowed to proceed with the steam that fills the steamer tank into which the continuous sliver sheet 51 with the scouring liquid is sent. The temperature inside the steamer tank 22a is preferably about 98 ° C. or higher and 105 ° C. or lower. If the temperature is too low, water vapor may condense and heat transfer may not proceed sufficiently. On the other hand, if the temperature is too high, an unexpected reaction may occur. The reaction time in the tank is preferably about 1 minute or more and 5 minutes or less. The vapor pressure of the steam to be introduced is preferably about 0.3 MPa or more and 0.7 MPa or less. By being squeezed by the pressure mangle device 21b, the surface of the continuous sliver sheet 51 is wet, but the water surface is almost nonexistent. Therefore, water vapor molecules, which are sufficiently smaller than liquid water droplets, easily come into contact with individual fibers, and a sufficient amount of heat can be quickly supplied to heat the fibers, so that the refining reaction can proceed in a short time. In order to facilitate the application of water vapor to the whole, it is desirable that the transportation medium for transporting the continuous sliver sheet 51 has holes for passing water vapor through the medium, such as a net-like conveyor.

Next, in the water washing machine 23, a water washing step 12c for washing the scouring liquid after the reaction adhering to the continuous sliver sheet 51 is performed.

In the water washing machine 23, it is preferable to wash the continuous sliver sheet 51 with water while transporting it with a perforated transport medium. Individual sliver sheets may unravel if they are independently immersed in a washing solution, but by placing or pinching them on a perforated transport medium, they can be prevented from unraveling and the sliver can be damaged. While preventing it, it is possible to continuously wash a large amount of slivers with water.

In particular, as a configuration for continuous washing with water so that the continuous sliver sheet 51 is not damaged, a net-like inner conveyor 53a and an outer conveyor 53b are used as perforated transport media, and the inner conveyor 53a and the outer conveyor 53b are used. When the continuous sliver sheet 51 is sandwiched between the two, soaked in the liquid, and exposed to a stream of water, the continuous sliver sheet 51 can be washed with water while being protected by the conveyors on both sides.

As the flush machine 23, it can be put into practical use even with a normal flush machine. However, if the water washing machine 50 having a liquid suction type structure is used, the merit of washing with water in the form of the continuous sliver sheet 51 can be maximized. Generally, the cleaning effect of 3 to 4 general replacement type washing machines can be achieved by one liquid suction type washing machine. Since the individual fibers of the continuous sliver sheet 51 are not twisted, the individual fibers can be quickly washed by causing liquid suction. Further, since the liquid suction can be washed with a smaller amount of water as compared with the case of washing in a static liquid, the amount of water used can be reduced. In the conventional method of continuously washing the yarn or woven fabric in a static liquid, a long water tank was required for washing with water. By using the flush machine 50 in the present invention, the water tank can be compactly organized, and an energy-saving factory can be realized in which the amount of land occupied and the amount of water consumed are significantly reduced.

The water washing machine 50 having a liquid suction type structure has a perforated drum 57 to be immersed in the water washing liquid, and has a suction device for sucking the water washing liquid from the inside of the perforated drum. Further, the inner conveyor 53a is arranged inside the continuous sliver sheet 51, the outer conveyor 53b is arranged outside the continuous sliver sheet 51, and the perforated drum 57 is sandwiched between the inner conveyor 53a and the outer conveyor 53b. It has a conveyor guide device that conveys the continuous sliver sheet 51 along the outer circumference of the sliver sheet 51.

A specific embodiment of the water washing machine 50 including the suction device and the conveyor guide device will be described. FIG. 3 shows a three-view view of an example of an embodiment of a suction type flush machine. 3A is a plan view, FIG. 3B is a front view, and FIG. 3C is a left side view. Of these, FIG. 4 shows an enlarged view of the vicinity of the perforated drum 57 in the center of the front view. Further, FIG. 5 shows a schematic diagram of the portion around the perforated drum 57 in these figures.

The continuous sliver sheet 51 is placed on a transportation medium and introduced into the water washing machine 50. Here, as the transportation medium, a chain conveyor (inner conveyor 53a and outer conveyor 53b) is shown as an example of the embodiment. After the continuous sliver sheet 51 is sandwiched between the inner conveyor 53a and the outer conveyor 53b and washed with water, the continuous sliver sheet 51 carried on the outer conveyor 53b is squeezed by the pressure mangle device 52 to remove excess liquid. .. FIG. 6 shows a photograph of an embodiment of the continuous sliver sheet 51 that receives the continuous sliver sheet 51 coming out of the pressurizing mangle device 52 by another chain conveyor 53c and is conveyed to the next.

The continuous sliver sheet 51 transported from the upper left in the figure is sandwiched between the outer conveyor 53b transported from the lower side and the inner conveyor 53a transported from the upper side, and introduced into the flush water of the flush tank 54. The inner conveyor 53a and the outer conveyor 53b and the continuous sliver sheet 51 sandwiched between them are the outer periphery of the perforated drum 57 immersed in the washing water of the washing tank 54 with the outer conveyor 53b facing outward. Introduced to be transported along. The perforated drum 57 is cylindrical and has a plurality of holes. These holes are large and large enough to allow a sufficient amount of flush water for washing the continuous sliver sheet 51 to pass through.

It has a conveyor guide device that surrounds a conveyor so as to continuously convey the continuous sliver sheet 51 along the outer circumference of the perforated drum 57. The conveyor guide device takes the outside of the perforated drum 57 so that the continuous sliver sheet 51 is sandwiched between a part of the inner conveyor 53a and the outer conveyor 53b, and they are continuously conveyed at the non-sandwiched portion. It is composed of a plurality of rollers as described later so as to rotate. It is preferable that a conveyor drive device for moving the conveyor itself is connected to a part of these rollers.

The inner conveyor 53a orbits the upper center of the figure as follows. The direction is changed downward by the roller 72b, and the continuous sliver sheet 51 is sandwiched between the outer conveyor 53b and the outer conveyor 53b sent from below to form a three-layer structure, which is transported in the lower right direction in the figure. It is hooked by a roller 56b to change the transport direction in the lower left direction in the figure, and makes a substantially circular rotation along the outer circumference of the perforated drum 57. At this time, the inner conveyor 53a comes into contact with the outer circumference of the perforated drum 57, but the continuous sliver sheet 51 goes around the outside of the inner conveyor 53a and does not come into contact with the perforated drum 57. When the drum 57 is separated from the perforated drum 57 in the three-layer structure, the transport direction can be changed in the upper right direction in the figure by the roller 56a. The continuous sliver sheet 51 follows the outer conveyor 53b and separates from the inner conveyor 53a while being placed on the outer conveyor 53b whose transport angle can be changed by the rollers 71a. The inner conveyor 53a is changed in the transport direction again by the roller 72a, and reaches the roller 72b again via the tension roller 73a of the tensioner 70a. Here, the tensioner 70a presses the inner conveyor 53a from above to apply a force so that the conveyor is transported without loosening. The location where the tensioner 70a is provided is not limited to the location shown in the figure, but it is preferable to provide the tensioner 70a at a location that does not overlap with the continuous sliver sheet 51. This is because if the tensioner 70a is arranged at the overlapping portion, extra tension is applied to the continuous sliver sheet 51, which may damage the sliver.

The conveyor drive device that moves the inner conveyor 53a itself moves so that the entire roller 72a is rotated according to the drive roller 68 that is rotated from the motor 66 via the chain 69. The roller 72a is not limited to this roller 72a. The continuous sliver sheet 51 sandwiched between the inner conveyor 53a and the outer conveyor 53b is rotated along the outer circumference of the perforated drum 57 by the mechanism for moving the inner conveyor 53a and the mechanism for moving the outer conveyor 53b described later.

On the other hand, the outer conveyor 53b orbits the inside and outside of the flush tank 54 as follows. The outer conveyor 53b sent from the left in the figure can change the transport angle in the lower right direction by the roller 71j, and the continuous sliver sheet 51 is sandwiched between the outer conveyor 53b and the inner conveyor 53a sent from above to form three layers. It becomes a structure and is transported in the lower right direction in the figure. Next, the transport direction is changed by the roller 56b, and the roller 56b makes a substantially circuit along the perforated drum 57 as described above. At this time, the inner conveyor 53a is on the inner side in contact with the perforated drum 57, the continuous sliver sheet 51 is sandwiched between them, and the outer conveyor 53b is arranged and transported on the outer side. The transport direction is changed to the upper right direction in the figure by the roller 56a, and the inclination of the outer conveyor 53b is gently changed by the roller 71a. At this time, the continuous sliver sheet 51 is separated from the inner conveyor 53a and placed on the outer conveyor 53b and sent to the contact points of the two rollers constituting the pressurizing mangle device 52. The outer conveyor 53b is transported in the opposite direction downward by the rollers 71b provided in front of the contact points of the two rollers. Further, the roller 71f provided on the lower side of the flush tank 54 via the roller 71c, the roller 71d, and the roller 71e in this order passes under the bottom surface of the flush tank 54 and is transported to the left in the drawing. be changed. The outer conveyor 53b is changed in the transport direction upward via the

rollers

71g and 71h, and the transport direction can be changed in a direction close to horizontal by the rollers 71i. It reaches the roller 71j via the tension roller 73b of the tensioner 70b, becomes a three-layer structure again, and circulates in the same manner. Here, the tensioner 70b also applies a force to press the outer conveyor 53b from above so that the conveyor can be transported without loosening. Similar to the inner conveyor 53a, the location where it is provided is not limited to the location shown in the figure, but it is desirable that the conveyor 53a is provided at a location that does not overlap with the continuous sliver sheet 51.

The conveyor drive device that moves the outer conveyor 53b itself moves so that the entire roller 71d is rotated according to the drive roller 68 that is rotated from the motor 66 via the chain 69. The roller 71d is not limited to this roller 71d.

The continuous sliver sheet 51 is sandwiched between the inner conveyor 53a and the outer conveyor 53b and transported along the outer circumference of the perforated drum 57. By transporting by this sandwiching, it is possible to prevent the sliver from breaking due to frictional resistance or contact resistance. Further, by sandwiching the continuous sliver sheet 51, introducing it while rotating it, and discharging it, the sliver having a light specific gravity and easily floating can be sequentially submerged in the liquid, preventing the fabric from floating and improving the permeability. ..

The inner conveyor 53a and the outer conveyor 53b are perforated transport media through which water flow can pass, and the perforated drum 57 that guides these movements also has a plurality of holes through which water flow can pass. Further, since the continuous sliver sheet 51 itself does not have individual fibers twisted, the structure is such that the individual fibers are easily exposed to the water flow. Further, a suction port 59 for sucking flush water in the axial direction from the vicinity of the center of the perforated drum 57 is provided. Negative pressure is generated inside the perforated drum 57 by pulling the washing water from the suction port 59 by the suction device, and the water in the washing tank 54 is the outer conveyor 53b, the continuous sliver sheet 51, the inner conveyor 53a, and the perforated drum. It passes through 57 in order and is sucked into the inside of the perforated drum 57. By being exposed to the flow, the continuous sliver sheet 51 is quickly washed with water. Since it is sandwiched and moved by a conveyor, there is no displacement or contact movement, and the liquid in the fiber can be replaced efficiently, so the washing efficiency is significantly higher than that of a simple washing machine.

The continuous sliver sheet 51 washed with water is squeezed with water by the pressure mangle device 52, and then carried to the next process in a state of being placed on the chain conveyor 53c.

Since the water in the flush tank 54 continues to be discharged to the outside of the system along with the continuous sliver sheet 51, it is desirable to supply water appropriately. Specifically, the water sucked from the suction port 59 provided in the axial direction of the center of the perforated drum 57 is introduced into the pump 63 via the suction pipe 62 going downward. The pump 63 serves as a suction device that sucks water from the inside of the perforated drum 57. Water is sent from the pump 63 to the upward delivery pipe 64. From the delivery pipe 64, the water is returned to the washing tank 54 from the spout 65 provided above the set water surface. On the other hand, the continuous sliver sheet 51 that has been washed with water may also be sent to the next bleaching step 13 after removing excess water through a pressurized mangle device 52 provided near the outlet.

Next, the bleaching step 13 will be described. The bleaching padder 31 performs an immersion step 13a, which is a preparation for the bleaching step 13. The basic apparatus and structure having the bleach immersion portion 31a and the pressurized mangle apparatus 31b are the same as those in the immersion step 12a performed by the scouring padder 21, and the bleach solution is adhered to the continuous sliver sheet 51. However, the bleaching solution used is different from the scouring solution.

The above bleaching solution is alkaline containing bleach. It is preferable that the pH is about 8.5 or more and 11.0 or less. Hydrogen peroxide solution can be preferably used as the bleaching agent, and if a penetrant that promotes wetting is contained, the permeation of the chemical solution proceeds rapidly, eliminating the need for equipment such as a pre-flushing tank and a chemical attachment tank. , It is preferable because the amount of water required for processing can be reduced. Further, it is preferable to have a hydrogen stabilizer and a reaction catalyst. As the alkaline agent to be adjusted to alkaline, a weakly alkaline agent such as sodium carbonate is preferably used.

The roll drawing condition of the pressure mangle device 31b on the outlet side of the immersion step 13a is preferably about 70 to 100%. However, a certain degree of wetness is ensured. The continuous sliver sheet in a wet state exhibits strength enough to maintain its shape even in the subsequent processing due to the friction of individual fibers.

Next, in the bleaching steamer 32, a steam heating step 13b is performed in which the continuous sliver sheet to which the bleaching liquid is attached is heated by the steam of the steamer tank 32a. As the conditions of the steamer tank 32a, the same conditions as those of the steamer tank 22a can be adopted. A continuous sliver sheet with bleaching liquid is sent in, and the steam filling the steamer tank causes a bleaching reaction. Although the content of the reaction caused by the heated bleach is different, it is desirable that the structure and conditions of the apparatus are basically the same as those in the scouring step 12. However, the reaction time in the tank of the bleaching steamer 32 is preferably about 6 minutes or more and 8 minutes or less. Although it takes longer than scouring, this reaction time can be significantly reduced to at most half or less, and in some cases one-fourth or less, compared to the reaction time when conventional bleaching is performed in a hot water bath. Is. Therefore, the energy and water consumption required for bleaching, which requires a processing load more than scouring, can be significantly reduced as compared with the conventional case.

Next, in the water washing machine 33, the water washing step 13c for washing the bleaching liquid after the reaction adhering to the continuous sliver sheet is performed. Similar to the above-mentioned washing step 12c, when the suction type washing machine 50 is used, it is possible to quickly wash the bleaching liquid without damaging the continuous sliver sheet 51 while reducing the amount of water required for washing the bleaching liquid.

After that, move to the post-process 14. First, the neutralization step 14a is performed by the neutralization padder 41. Even after washing with water after bleaching, the continuous sliver sheet 51 is alkaline due to the bleaching solution, so this is made neutral. After that, the hot water washing step 14b is performed with the hot water washing shower padder 42 to finish the process.

Note that other functional processing may be performed in this post-process or before or after the post-process. For example, durable flexible processing, washing durability processing, antibacterial processing, quick-drying function processing, sweat odor deodorant processing, aging odor deodorant processing, water repellent processing and the like. FIG. 7 shows an example of a flow in which the function imparting step 17 is performed after the post-process. Except for the function-imparting step 17, it is the same as the above-described embodiment shown in FIG. As the function-imparting step 17, in the immersion step 17a of immersing the continuous sliver sheet, the function is immersed in a chemical solution corresponding to the function to be imparted. In the immersion step 17a, a chemical solution corresponding to each of the above processes is used. Further, a chemical solution corresponding to a plurality of these processes may be used. After the neutralization step 14a and the hot water washing step 14b are completed in the post-step 14, the sliver is neutral and easy to handle, is in a state where impurities are removed, and is easy to react with a chemical for processing. Moreover, since it is a sliver, the chemicals for functional processing are not easily disturbed by each other's fibers, and the chemicals can be preferably and quickly permeated and the effect can be exhibited. After that, the liquid component can be removed in the drying step 17b to obtain a highly effective sliver. This sliver can be spun in the spinning step 15 to obtain a cotton product having a function appropriately imparted to each fiber. As a result, the amount of water and energy required for functional processing and the space required for processing are greatly reduced compared to the case where the function is added in the state of yarn or woven fabric as in the past. be able to.

Although not shown, it is advisable to dry the sliver with the continuous sliver sheet 51 as it is. A wet sliver sheet exhibits a certain level of strength because the frictional force between fibers increases, but this strength decreases when it dries. Therefore, it is desirable to dry the product while it is placed on the perforated transport medium. Further, it is preferable that the structure has a device controlled to prevent excessive scattering due to air volume, wind speed, and wind pressure during drying. Hot air is blown out from above and below the object to be dried inside the dryer, but it is more preferable to have a structure that allows hot air to easily pass through the gaps between the fibers of the continuous sliver sheet due to the structure of the outlet. The heat source required for drying may be steam, gas, or an electric heater. The temperature of the applied heat is preferably variable from 70 ° C. to 180 ° C. depending on the material of the cotton material to be dried. As a result of the continuous sliver sheet being sufficiently dried, a continuous sliver sheet having a bulge similar to the shape of the continuous sliver sheet at the time of charging can be obtained by the function of the dryer capable of controlling the wind pressure and the air volume.

In this way, a bleached sliver or a sliver that has been functionally processed can be obtained. The obtained continuous sliver sheet is formed into the shape of a gellens river and then spun (spinning step 15). To become a Gerence River, you may choose either the following first or second method. In the first method, a gellens river for yarn spinning is created after passing through a blending cotton machine, a card machine, etc., and a kneading machine in the same manner as in a normal raw cotton spinning process. In the second method, the sliver having a shape of being separated and distributed one by one can be directly put into a kneading machine to create a gellens river for yarn spinning. Either the first method or the second method may be used, and the Gerence River can spin various counts of functional spun yarn with a desired count. Of these, the first method requires a manufacturing process and time, resulting in high cost. On the other hand, in the second method, the processed sliver can be directly put into the kneading machine, so that the spun yarn can be manufactured in a short time without high cost, which can contribute to the rationalization of production. In order to carry out the second method, it is necessary to separate the sheet-like sliver into one sliver through a sliver separation device after drying, but the device is already a sliver separation and distribution device so that it can be added according to demand. It is desirable to be prepared as.

When obtaining a cloth or a practical product, a step of combining threads to obtain the cloth and a step of cutting and sewing the cloth to make it into a required form are added after the step of FIG.

An example is shown in the case where the sliver is scoured and bleached by steam according to the present invention. The evaluation of whiteness was expressed by JIS whiteness and Hunter whiteness, and the measurement of whiteness was performed by a CR410 color difference meter manufactured by Konica Minolta. The results are shown in Table 1 below.

(Examples 1 and 2)
In the steam scouring step, scouring was performed with a scouring solution having the composition shown in Table 2 below. Acid scouring agent …… Chemist DN (manufactured by Satoda Kako), acid resistant penetrant …… anisole MA-27 (manufactured by Satoda Kako), enzyme catalyst …… AC600 (manufactured by Rakuto Kasei Kogyo), degassing penetrant …… MAC- N2 (manufactured by Kitahiro Chemical Co., Ltd.). After the liquiding treatment with a scouring padder at room temperature, the treatment was carried out with steam at 100 ° C. for 3 minutes, and then washed with water using the suction water washing machines shown in FIGS. 3A to 3C and FIG. After that, the following bleaching was performed.

(Comparative Example 1)
In batch scouring performed by immersing in a scouring solution, the processing machine manufactures a stainless steel open basket to be placed in the cheese dyeing machine manufactured by Hisaka Works, which is described in Japanese Patent No. 554172, and a sliver is set in the open basket for processing. It was. It was treated at a liquid temperature of 50 ° C. for 30 minutes, washed with water, and then steam bleached under the same chemicals and conditions as the bleaching of Example 1.

(Examples 1 and 2, Comparative Example 1: Bleaching)
Both bleaches were steam type. The bleaching padder was coated with a bleaching solution and treated with steam at 100 ° C. for 3 minutes. After that, the bleaching liquid was squeezed with a pressurized mangle machine at the outlet, and then washed with water using the suction type water washing machines shown in FIGS. 3A to 3C and 4 to neutralize and wash with hot water. The composition of the bleaching solution is shown in Table 3 below. The drugs used are as follows. That is, bleach: 35% hydrogen peroxide (made by ADEKA), penetrant: MAC-25S (made by Kitahiro Chemical), stabilizer: Hoctol 110 (made by Kitahiro Chemical), stabilizer: Neolate PL-3 (made by Kitahiro Chemical). Nikka Kagaku), reaction catalyst: Catalyst OX (Satoda Kako), alkaline agent: sodium carbonate (soda ash) (Tokuyama). The pH was 10.3.

The process time was 3 minutes for steam scouring and 30 minutes for batch prescription scouring. The amount of liquid to be treated is about the same as the amount to be processed in steam scouring, whereas the amount of liquid to be processed in batch prescription scouring requires about 10 times the amount of processing. Therefore, in batch prescription scouring, the processing time is longer and the amount of drainage of the processing liquid is increased as compared with steam scouring. Therefore, according to the present invention, the environmental load can be reduced and energy can be reduced in a short time with a low displacement. It can be said that it is connected. In addition, the whiteness of the steam scouring treatment was higher than that of the batch scouring treatment, and the whiteness was higher when the degassing penetrant was used, and the actual quality could be improved.

11 Source 12 Smelting process 12a Liquid immersion process 12b Steam heating process 12c Water washing process 13 Bleaching process 13a Liquid immersion process 13b Steam heating process 13c Water washing process 14 Post-process 14a Neutralization process 14b Hot water washing process 15 Spinning process 17 Function-imparting process 17a Liquid immersion process 17b Drying process 21 Smelting padder 21a Smelting liquid immersion part 21b Pressurized mangle device 22 Smelting steamer 22a Steamer tank 23 Water washing machine 31 Bleaching padder 31a Bleaching liquid immersion part 31b Pressure mangle device 32 Bleaching steamer 32a Steamer tank 33 41 Neutralization padder 42 Hot water washing shower padder 50 Water washing machine 51 Continuous sliver sheet 52 Pressurized mangle device 53a Inner conveyor

53b Outer conveyor

53c Chain conveyor 54

Water washing tank

56a, 56b Roller 57 Perforated drum 59 Suction port 60 Overflow 62 Suction piping 63 Pump 64 Delivery pipe 65 Spout 66 Motor 68 Drive roller 69

Chain

70a, 70b Tensioners 71a to 71i

Rollers

72a, 72b (for outer conveyor)

Rollers

73a, 73b Tension rollers

Claims

A method for manufacturing cotton-containing products, in which the cotton material is scoured and bleached in a sliver state.
The method for producing a cotton-containing product according to claim 1, wherein the cotton material to which a chemical is applied is heated by steam during the scouring and the bleaching.
The method for producing a cotton-containing product according to claim 2, wherein when the heating is performed, the steam is applied in the state of a sliver sheet in which the slivers are arranged in a sheet shape.
The method for producing a cotton-containing product according to claim 3, wherein the sliver sheet is washed with water while being transported by a perforated transport medium after being heated by applying the steam.
As the perforated transport medium, a net-like inner conveyor and an outer conveyor are used.
Immerse the perforated drum in a washing liquid and arrange it.
The inner conveyor is arranged inside the sliver sheet, and the outer conveyor is arranged outside the sliver sheet.
With the sliver sheet sandwiched between the inner conveyor and the outer conveyor, the sliver sheet is conveyed along the outer periphery of the perforated drum, and the washing liquid inside the perforated drum is sucked to suck the sliver sheet to the outside. The method for producing a cotton-containing product according to claim 4, wherein the sliver sheet is washed with water by passing a washing liquid from the outside of the conveyor through the outer conveyor, the sliver sheet, the inner conveyor, and the perforated drum in this order.
The method for producing a cotton-containing product according to any one of claims 1 to 5, wherein the cotton material imparts a function in a sliver state after the bleaching is completed.
The method for producing a cotton-containing product according to any one of claims 1 to 6, wherein spinning is performed using the bleached sliver.
Bleached cotton sliver.
A cotton-containing product manufactured by using the sliver according to claim 8.
A perforated drum immersed in a washing liquid and
A suction device that sucks the washing liquid from the inside of the perforated drum,
A pair of mesh inner and outer conveyors that sandwich the sliver sheet,
The inner conveyor is arranged inside the sliver sheet, the outer conveyor is arranged outside the sliver sheet, and the sliver sheet is sandwiched between the inner conveyor and the outer conveyor along the outer circumference of the perforated drum. It has a conveyor guide device for transporting the sliver sheet.
When the suction device sucks the washing liquid inside the perforated drum, the washing liquid is passed through the outer conveyor, the sliver sheet, the inner conveyor, and the perforated drum in this order from the outside of the outer conveyor. A suction type flush machine that flushes the sliver sheet with water.
It is a production line that continuously performs a scouring process and a bleaching process for cotton materials.
For at least one of the scouring step and the bleaching step
The suction-type water washing machine according to claim 10, wherein the steamer in which the sliver sheet made of cotton material is immersed in water and the sliver sheet after immersion is heated by applying steam, and the sliver sheet after heating is washed with water. A production line for cotton-containing products.