US3771953A - Yarn bulking method - Google Patents

Abstract

A method of bulking yarn in package form comprises subjecting yarn in a substantially tensionless package to a heated fluid. Also, apparatus for performing the method and the bulked package.

Description

United States Patent 1191 1111 v Eschenbach et a]. Nov. 13, 1973 [54] YARN BULKING METHOD FOREIGN PATENTS OR APPLICATIONS lflvemorsi Paul Eschenbach; Jerry King; 318,236 9 1930 Great Britain 68/189 Dennis L. Riddle, all of Spartanburg, SC.

[73.] Assignee: Deering Milliken Research Primary Examiner-William? Price Corporation, Spartanburg, Attorney-Norman C. Armltage et a1.

[22] Filed: Sept. 16, 1971 [2]] App]. No.: 181,069

57 ABSTRACT 52 U.S. Cl. 8/149.3 51 1111.01. D06c 1/00 A method Of bulking yarn in Package form comprises 58 Field of Search 8/149.1, 149.2, 149.3, subjecting y in a Substantially tensionless Package 3/154 155 155 1 1551; 3 1 9 3; 2 5 B to a heated fluid. Also, apparatus for performing the method and the bulked package.

[56] References Cited UNITED STATES PATENTS 1 Claim, 18 Drawing Figures 3,528,180 9/1970 Karrer et a1. 8/149.l X

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PATENIED W 13 I975 SHEEI 2 UP 7 FIG-9- QOOOOOOOOOQ PAIENIEDuuv 13 1915 SHEEI MIF 7 I PATENTEU NEW 1 3 1973 SHEET 7 OF 7 OOOOOOOO w M u w wL O 8 9O FIG- l6- YARN BULKING METHOD This invention relates to a novel method and apparatus for treating textile yarns to increase the bulk thereof. More particularly, the invention relates to a method and apparatus for bulking yarn in package form.

One commonly employed method for bulking yarns is the skein dyeing process. In skein dyeing the yarn to be bulked is wound into skein form from bobbins or cones and the skeins loaded on a large carrier by draping the skeins over horizontally mounted poles. The carriers loaded with skeins are placed in a dye bath to dye the yarn and to simultaneously bulk the yarn. After the dyeing and bulking are completed, the skeins are centrifuged to extract excess liquid and then backwound into packages which are dried in an oven prior to shipping.

The present invention provides a novel method and apparatus for bulking yarn in a wound package form with a high degree of uniformity along its length. The invention also provides a novel method for providing polyester yarns having a substantially higher degree of bulk than is achievable by the skein dyeing process. A further advantage of the invention is the bulking in a package form suitable for subsequent pressure dyeing methods. Another advantage is the bulking of single packages which permits the bulking apparatus to be located adjacent the winding apparatus.

A method of the invention for bulking yarn in package form comprises subjecting yarn in a substantially tensionless package to a heated fluid. Advantageously, the heated fluid is passed through the yarn package from the inside to the outside thereof or vice versa in the modification, and preferably, the fluid flow is advanced along the length of the package from one end to the other. The fluid generally is an aqueous fluid and particularly steam above or below atmospheric pressure.

Yarn packages suitable for bulking in accordance with the method of the invention are packages in which the yarn is in a substantially tensionless condition. In one yarn package configuration which may be,employed successfully, yarn is disposed around a central corein a helical pattern so that the yarn forms a package composed of an ascending series of loops in which the yarn is adjacent the core along one portion of each loop and adjacent the periphery of the package at another portion thereof. Examples of suitable patterns are shown in FIGS. 3-5 of- Polak et al., U.S.- Pat. No. 2,404,742, with the pattern of FIG. 5 being preferred.

The method of the invention will be described in greater detail with reference to the accompanying drawings, in which:

FIGS. 1-9 are schematic illustrations of' one processing sequence of the bulking method of the invention;

FIG. isan exploded perspective view of one form of apparatus for performing the 'bulking' method of the invention;

FIG. 11 is an exploded perspective view of the appa v ratus shown in FIG. 10 during another step in the bulking method of the invention;

FIG. 12 is an enlarged side elevation of the apparatus shown in FIG. 10; I

FIG. 13 is an enlarged sectional view of the dome portion of the apparatus shown in FIG. 10;

FIG. 14 is a sectional view taken along line l414 of FIG. 13;

. posed over a movable nozzle 14. Below the package 11 and surrounding the nozzle 14 is a plenum chamber 15. The base 13 includes a peripheral flange 17 which engages rim 18 of dome 19. Dome 19 has a line 20 for introducing an inert gas into the dome and also a pressure gauge 21. The dome also includes an inner conical portion 22. A line 23 for exhausting gas from the vicinity of the package connects to base 13. As shown in FIG. 2, the dome 19 is disposed over the package 11 with cone 22 in contact with the package and flange 17 engaging rim 18 to form a treating chamber. In FIG. 3, a flow of air is introduced through line 20 to pressurize the chamber. FIG. 4 shows the start of the heat treating step with a heated fluid, e.g., steam, being forced from nozzle 14 into plenum chamber 15. This flow of steam into plenumchamber 1 5 advantageously is performed prior to the beginning of the steaming step to insure that the velocity of the steam and the temperature of the nozzle 14 are within operating limits before the steam contacts the yarn and the nozzle advances through the package 11 as shown inFIG. 5..This condition is particularly important with yarns such as polyester yarns with which full bulking cannot ordinarily be achieved if partial bulking has taken place prematurely. Passing of the steam flow through the. package causes the yarn to shrink and bulk and reduces the size of the package as the nozzle advances therethrough. This is shown in FIGS. 5 and '6. After the steaming step has been completed,-the nozzle 14 is withdrawn from the interior of the package as shown in FIG. 7 and a flow of inert gas is introduced into the chamber through line 20. Any steam and condensate in the treating chamber is exhausted through line 23. As shown in FIGS. 8 and 9, the flow of inert gas'is continued as the dome 19 is moved from around bulked package 11. The bulked package 11 is then removed from the base 13, and the sequence is repeated with a new yarn package.

While the above-described sequence of operations, as shown in FIGS. 1-9 of the drawings, is important to achieve a high degree of bulk with yarns which are difficult to bulk such as those including polyester fibers, the sequence may be simplified for the processing of yarns which bulk readily. For example, acrylic yarns maybe bulked without the initial pressurization with inert gas as shown in FIG. 3. Also, it is not critical that the fluid'treatment' bedoneas the nozzle is moved through the core 12 of the package. For example, the heat treatment may be accomplished when the nozzle 14 is in its upper position as shown in FIG. 6 of the drawings or the heated fluid may be introduced through gas line 20 and the nozzle eliminated. This simplification of the processing sequence generally is permissible with yarns that bulk easily and can be bulked successfully with known processes such a'sskein dyeing. However, as pointed out above, in the case of polyester yarns which cannot be bulked to a high degree by a skein dyeing process, it is preferred that the initial pressurization and the particular steaming sequence utilizing a moving nozzle shown in FIGS. 4 and 5 of the drawings be employed.

The processing sequence particularly suitable for the bulking of polyester yarn subjects the yarn to an inert gas at a super atmospheric pressure prior to the heat treating step. Suitable gases include air, nitrogen, carbon dioxide, argon and similar gases which are inert to the yarn. Both the inert gas and the succeeding hot fluid treatment are performed at a super atmospheric pressure, for example, between about 2 and 50 pounds per square inch gauge pressure and preferably between about 5 and psi. While the inert gas treatment generally is performed at ambient temperatures, the hot fluid treatment will be at an elevated temperature, usually between about 220 and 280F.

Whre the fluid treatment of the yarn package is accomplished while the nozzle advances through the package from one end to the other, it is desirable that the nozzle have an orifice which will pass the fluid through the package from the inside to the outside thereof with sufficient velocity to uniformly bulk the package. For example, a steam flow rate between about 5 and 25 pounds per minute advantageously may be employed. Advantageously, the nozzle orifice deflects the fluid in a slightly downward or backward direction during the advance through the package.

One preferred form of apparatus for performing the bulking method of the invention is shown in FIGS. l012 of the drawings. In FIG. 10, a yarn package is positioned on a support 31 disposed above a base 32. A dome 33 is located concentrically with package 30 and movable longitudinally into contact with base 32. Movement of dome 33 is achieved with a cylinder 34 which is operatively connected thereto through bracket 35. The movement of the dome is controlled by a plurality of guide rollers 37 and 38 which. contact support member 39. Support member 39 has an opening 41 therein for safety stop piston 42 of cylinder 43. When dome 33 is in a position surrounding the yarn package 30, roller 38 engages a spring actuated rod 44 with suit able projections which engage sensing switch 45.

Dome 33 has an air line 47' connected thereto to provide for the flow of a gas into the dome cavity. Disposed within the upper portion of the dome is a cone 48 which engages the upper portion of the yarn package 30 when the dome surrounds the package. A weir 49 is positioned within the lower portion of the dome to collect any water condensing on the inside walls of the dome. Rim 51 of the dome 33 includes a pair of cam surfaces 52 for securing the dome to the base 32 through a locking ring assembly 53. The locking ring assembly has a periphery which is movable by means of cylinder 54 and a plate 55. A switch 56 is positioned adjacent cylinder 54 to sense movement thereof. Rollers 57 are mounted in association with the locking ring assembly 53 through brackets 58 for engagement with the cam surfaces 52 of the dome flange 51 when the lock ring assembly is rotated to the closed position. A spring loaded locking pin 59 is disposed for engagement with an opening in plate 55 when the locking ring assembly 53 is in its closed position. A sensing switch 60 is located adjacent locking pin 59.

A nozzle 61 is positioned in a central opening of base 32 as shown in FIG. 12. A seal 62 is disposed within the opening and bears against the surface of the nozzle.

Nozzle 61 has a transverse opening 63 adjacent the end thereof through which the fluid is emitted. In the normal rest or downward position of the nozzle 61, the transverse opening 63 is located within a plenum chamber 64 disposed below the base 32. Drains 65 are positioned about the periphery of the base 32 to permit the removal of fluid and/or condensate formed during the processing of the yarn. Fluid is transmitted'to the nozzle 61 through a line 67 including a valve 68 as shown in FIGS. 10 and 11.

The nozzle is moved vertically during processing by a drive mechanism including chains 69 and sprockets 70 and 71. Sprockets 71 are connected through shaft 72 to pinion gear 73 which engages rack 74. Rack 74 is actuated by cylinder 75. The movement of nozzle 61 is guided by roller 77 moving along guide rail 78. Guide roller 77 is connected to nozzle 61 through a bracket 79. The action of cylinder 75 is controlled by limit switches 81 and 82 positioned to engage the guide bracket 79 at the upper and lower extremities of the nozzle movement.

In the operation of the apparatus shown in FIGS. 10-12, a yarn package 30 is positioned on support 31, and suitable controls (not shown) are actuated causing piston 42 to withdraw from opening 41, removing the safety stop from the path of dome 33 so that dome 33 is lowered by the action of cylinder 34 into contact with base 32. When this contactis established roller 38 bears against connecting rod 44 to actuate switch 45. Thereafter, cylinder 54 rotates locking ring assembly 53 so that rollers 57 engage cam surfaces 52 of the dome flange 51. When the locking ring assembly reaches its closed position, pin 59 engages an opening in plate to lock the ring and base to the dome.

The processing cycle then is performed following the sequence shown in FIGS. 19 of the drawings. Progressive steaming is accomplished by actuating cylinder-75 which moves rack 74 and thereby rotates pinion gear 73 and sprockets 71, moving chains 69 which are secured to bracket 79. This movement raises the nozzle 61 and advances it through the central core of the package. The heated fluid is emitted from transverse opening 63 of the nozzle by valve 68 and through line 67. Upon completion of the heat treating step, the contact of switch 81 by bracket 79 reverses the action of cylinder 75 and rack 74 so that sprockets 71 rota'te'in the opposite direction moving the nozzle 61 to its lower or normal rest position. After the inert gas has been introduced into the dome through line 47 and the condensate removed through drains 65, locking pin 59 is withdrawn and cylinder 54 is reversed unlocking ring assembly 53. Thereafter, the actuation of cylinder 34 raises dome 33 to its most upward position and cylinder 43 moves piston 42 into opening 41 to provide a safety stop against accidental dropping of the dome. This permits the bulked yarn package to be removed from support 31. A new package then is inserted for bulking and the operation repeated.

In treating certain yarn, such as acrylics, at elevated temperatures, the yarn is bulked excessively as comaas the steam nozzle is driven upwardly. In the modification of FIGS. 16-18 the steam is not ejected until the nozzle 14 reaches the position shown in FIG. 17 so it is desirable for uniform bulking efficiency at low pressure within the dome, to cause the steam to flow through the package from outside to inside.

To accomplish the desired result the support 31 and base 32 were eliminated and the plenum member 80 substituted therefor. Suitable screw members 82 secure the plenum member 80 to the locking ring assembly 53 so that the plenum member 80 supports the yarn package 30 thereon.

in operation steam flows from the nozzle 14 due to the action of steam ejector 88 and flows initially outward, then inward through the package 30 down through the opening 84 in the plenum member 80 into the plenum chamber 81, out through the condensate lines 65, through the steam ejector 88 into the drain conduit 90. It can readily be seen that if the plenum member 80 was not employed the steam and/or condensate would tend to by-pass the package and flow directly down to the condensate lines 65 the steam ejector 88 is used to pull the steam out the nozzle since the pressure in the dome is greater than the steam pressure.

The above description and drawings show that the present invention provides a novel method and apparatus for bulking yarn in a tensionl'ess package configuration. Furthermore, the method of the invention results in a product having a high degree of bulk uniformity along the length of the packaged yarn. Moreover, the invention enables polyester and acrylic yarns to be bulked to a substantially higher degree than is achievable by skein dyeing processes. Also, the bulked yarn package is suitable for use in pressure dyeing techniques. In addition, since the apparatus permits the bulking of single packages, the bulking apparatus may be located adjacent the package winding station. This minimizes the possibility of damage to the packages which have been wound in a loose, substantially tensionless form.

From the above description and drawings, it will be apparent that further modifications and variations may be made in the described method and apparatus within the scope of the present invention. For example, certain steps of the bulking method may be rearranged and/or eliminated for particular yarns. Also, movement of the dome and the nozzle may be achieved by other means. Therefore, the invention is to be limited only by the following claims.

That which is claimed is:

1. A method of bulking acrylic yarn in package form comprising the steps of: forming a plenum chamber with an opening therein, placing a package of acrylic yarn over the opening in said plenum chamber, enclosing the exterior of package of yarn from ambient atmospheric conditions, passing steam into an area outside of said package, ejecting steam from said plenum chamber to cause said steam outside of said package to pass through said package and into said plenum chamber.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 7 1,95 Dated November 13, I973 I Paul W. Eschenbach; Jerry N. King; Dennis L. Riddle It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

7 Column 4, lines-'60 and 61 "comapred" should read compared--. In Claim 1, line 24, 1:he-- should be inserted between the first "of" and "package".

-..3igned and sealed this 30th day of April 1972;.

(SEAL) Attest: I

EDWARD M.I*LETGHER,JR. c MARSHALL DANN Attesting Officer I Commissioner of Patents FORM 50-1050 (10-69) USCOMM-DC scan-Pan apis. GOVERNMENT ram-nus Offlc! up o-qcgfl'sy

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