Bleaching and dyeing; fluid treatment and chemical modification – Fluid treatment – Special forms and forming
Reexamination Certificate
1999-09-09
2001-05-15
Coe, Philip R. (Department: 1746)
Bleaching and dyeing; fluid treatment and chemical modification
Fluid treatment
Special forms and forming
C068S027000, C068S189000
Reexamination Certificate
active
06231620
ABSTRACT:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a low ratio yarn package treatment apparatus and method. Most modem yarn dyeing is carried out after the yarn has been wound onto suitable packages and formed into cheeses, cones or cakes, which are then mounted onto perforated spindles carried on a yarn package carrier. The loaded carrier is then placed into a pressure vessel, and the yarn is dyed by forcing a liquor of water, dye and perhaps various additives through the packages. Early machines were open to the atmosphere and dyeing took place only from the inside to the outside of the package, i.e., the dye liquor was forced from the perforated spindles through the yarn from the inside of the package to the outside. The liquor was then withdrawn from the vessel and recirculated in the same manner.
Later machines were enclosed, and by reversing a liquor pump, liquor could be alternately forced through the yarn from the inside to the outside and then from the outside to the inside. This process remains the most commonly used, because the alternating inside-out, outside-in dyeing results in the most uniform dyeing of the yarn.
In conventional package dyeing machines, the liquor ratio is relatively constant and is based on the weight of the yarn which can be dyed in a given capacity vessel. The “ratio” is based on the weight of yarn that can be dyed using a given weight of liquor. Thus, a ratio of 10:1 refers to a dye process where, for example, 10,000 pounds of liquor is required to dye 1,000 pounds of yarn. This normally occurs when the vessel is fully flooded, completely covering the yarn package carrier and filling even the domed cover of the vessel.
While this practice generally provides the best dyeing results, particularly with deep shades, this large ratio results in a considerable amount of dye being left over in the liquor after dyeing is complete. The dye is typically dumped with the waste water into a nearby river or sewer, or into a wastewater holding area or treatment facility. Increasingly strict government regulation in many areas now limits the extent to which wastewater containing dyes and other yarn treatment additives can be disposed of without expensive treatment processes.
These requirements, as well as demands for energy conservation, reduced dyeing costs and faster dyeing times have led to techniques whereby varying amounts of dye liquor are used in order to reduce the liquor ratio. One such technique involves partially flooding the vessel to above the level of the packages, but leaving the dome of the vessel unfilled, thus reducing the liquor ratio to about 8:1. Another technique involves a low-liquor state in which only the base of the carrier is covered with dye liquor. The liquor is pumped up through the spindles of the carrier and through the packages from the inside-out. Liquor ratios can be reduced to 4:1 or even 3:1 using this technique. However, dyeing can take place only in the in-to-out flow direction. The packages must be sufficiently rigid not to distort under these conditions. Significant economies can be obtained by reducing the liquor ratio in this manner. However, the economies obtained are often outweighed by difficulties with dye solubility, dispersion stability and dyeing unevenness, particularly where deep shades are being imparted to the yarn.
The present invention achieves low ratio dyeing on the order of 4:1 or 3:1 while nevertheless permitting full submersion of the yarn packages and alternating in-to-out and out-to-in dyeing. This is accomplished while otherwise carrying out conventional dyeing processes using conventional dyes and additives, and with equipment which can be modified from conventional dyeing equipment.
While dyeing is described in this application as a preferred embodiment of the practice of the method of the invention, the invention is intended to apply to all types of yarn treatments wherein yarn is wet-processed in a dye vessel. It is believed that the invention may have broad application to the dyeing of fibers in the form of raw stock, various yarn forms and even in apparel form, consistent with the principles set out in this application.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a yarn package treatment apparatus and method for treating yarn packages at low liquor ratios.
It is another object of the invention to provide a yarn package treatment apparatus and method for treating yarn packages at low liquor ratios while subjecting the yarn packages to alternating in-to-out and out-to-in liquor flow.
It is another object of the invention to provide a yarn package treatment apparatus and method for treating yarn packages at low liquor ratios using equipment easily modified from existing conventional yarn package dyeing equipment.
It is another object of the invention to provide a yarn package treatment apparatus and method for treating yarn packages at low liquor ratios with conventional dyes and additives.
These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a low ratio yarn treatment apparatus for dyeing yarn packages mounted on perforated spindles, comprising a first vessel for holding a first spindle-mounted array of yarn packages to be treated and a second vessel for holding a second spindle-mounted array of yarn packages to be treated. A first conduit is provided in liquor flow communication with the first vessel and the second vessel for permitting treatment liquor to flow therebetween and a second conduit is provided for being connected in liquid flow communication with perforated spindles positioned in the first vessel and with perforated spindles positioned in the second vessel for permitting treatment liquor to flow between the perforated spindles in the first vessel and the perforated spindles in the second vessel. Pump means is provided and cooperates with the first conduit for inducing flow of the treatment liquor to a desired level within the first vessel and second vessel, and inducing flow of the treatment liquor in alternating directions between the first vessel and the second vessel and cooperating with the second conduit for inducing flow of the treatment liquor in alternating in-to-out and out-to-in directions between perforated spindles positioned in the first vessel and perforated spindles positioned in the second vessel.
According to one preferred embodiment of the invention, the pump means comprises a first reversing pump cooperating with the first conduit for inducing flow of the treatment liquor in alternating directions between the first vessel and the second vessel, and a second reversing pump cooperating with the second conduit for inducing flow of the treatment liquor in alternating in-to-out and out-to-in directions between perforated spindles positioned in the first vessel and perforated spindles positioned in the second vessel.
According to another preferred embodiment of the invention, the spindles are positioned on a yarn carrier base, and the yarn carrier base includes a port communicating with the second conduit and the perforated spindles for permitting alternating liquor flow to and from the second conduit and into and out of the spindles.
A method of low liquor ratio treatment of yarn packages mounted on perforated spindles positioned on respective first and second yarn carriers, comprises the steps of providing first and second treatment vessels interconnected by liquor flow conduits wherein flow is induced by pumps, each of the first and second treatment vessels adapted to receive a respective one of the first and second yarn carriers therein for treatment of the yarn. The first treatment vessel is filled with sufficient treatment liquor to cover all of the yarn packages on the yarn carrier therein while leaving the yarn packages in the second treatment vessel substantially uncovered by the liquor. The liquor is pumped for a predetermined period of time from the first treatment vessel through the yarn packages from the outside to the inside
Adams, Schwartz & Evans P.A.
Coe Philip R.
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