| JP2005245385 | AGRICULTURAL LIGHT-REGULATING CURTAIN |
| JP2011084822 | FABRIC |
| JP2002115137 | FLAT YARN HAVING PEARL GLOSS OR COHERENT PEARL GLOSS AND CONJUGATE YARN USING THE SAME |
TASKOPARAN, Erdinc (Keresteciler Sitesi Fatih Cad, Selvi Sokak No:18 Merter, Istanbul, 34169, TR)
CLAIMS
1. The invention is the method for obtaining fabric having high breakage and tearing strength in weft and/or warp direction and having higher resistant increase relative to existing cotton woven fabrics by means of yarn dyeing and warp dyeing technique and it is characterized in that it comprises of the process steps of:
- Application of transferring process to the filament yarn made of HDPE fiber at folding machine,
- Making the filament yarn made of HDPE fibre ready for operation by means of hanging on hanger and creel system where hanger is connected, before putting it in ring machine,
- Upon making it ready for work at ring yarn machine, hanging the filament yarn made of HDPE fiber onto creels on the machine together with cord made of cotton, - Subjecting the cotton cord to drafting as per the number at ring machine drafting roller,
- Realization of centering process in a manner filament yarn of HDPE fiber in the core (center) and cotton fibers covering around,
- Conduct of double bath sizing to the fabric, - Sizing the high resistant yarn containing HDPE fiber and 100% cotton indigo yarn in separate baths and setting of tension settings of both baths separately and brining it to the same tension at the point where they connect,
- Rolling of high resistant yams containing HDPE fiber in 8-16 ropes preferably 12 ropes.
- Rope rolling cross-guiding at 300-800 m preferably at every 500 m so as to prevent yarn breakage,
- Cross-yarn in between so as to distinguish between two warps at rolling end, - Loading of yarns onto creels at skipping and at odd numbers so as to increase the distance between ropes
- Setting of the engine thermic opening times according to tension values of ropes, - performance of dyeing in 8-16 ropes, preferably 12 ropes,
- Subjecting the prepared denim fabric to brush machine for removal of fibers and then burning process for removal of hairs.
- Cooling at cooling barabans
- Subjecting to the basic solvent of certain volume and quantity, - Drying and drying barabans so as to enable better finishing of the fabric after washing,
- Application of finishing after drying process,
- Subjecting the fabric to drying again
- Passing it through heated rubber and felt blanket for sanforizing process,
- Sending it to cooling barabans as the fabric from the felt blanket is too hot.
2. A production method according to claim 1 and it is characterized in that it is cleaned so as to ensure that warp indigo or gabardine is on the upper part and HDPE containing high resistant yarn is on the lower part for double layered HDPE fiber containing fabric production and that the tension setting of the machine is performed.
3. A production method according to claim 1 and it is characterized in that high resistant yarn containing HDPE is used in warp and 100% cotton yarn is used in weft.
4. A production method according to claim 1 and it is characterized in that knotting method is used in rope rolling and unrolling.
5. A production method according to claim 1 and it is characterized in that machine rpm is between 280 wefts/minute and 320 wefts/minute.
6. A production method according to claim 1 and it is characterized in that warp torsion degree is 7 to 9.
7. A production method according to claim 1 and it is characterized in that a single card of 334.8cm is used and thickness strength of 3.5 mm to 4.0 mm hole diameter is used.
8. A production method according to claim 1 and it is characterized in that the denim fabric passed through the said cooling barabans is passed through 8-12 borne NaOH solvent of 400-600 It.
9. A production method according to claim 1 and it is characterized in that the said fabric is subjected to basic solvent at bath compression pressure of 60 psi and 80 psi and check for time periods of 10 minutes and 20 minutes.
10. A production method according to claim 1 and it is characterized in that a material preventing fold of fabric edge frequently is used in order to prevent folding the fabric in steam unit after pre-treatment. 11. A production method according to claim 1 and it is characterized in that the drying process of said fabric in drying barabans after washing is realized under drying pressure of 4 bar to 5 bars and drying temperature of 13O 0 C to 145 0 C .
12.A production method according to claim 1 and it is characterized in that the finishing process is realized by means of finishing agent providing softness and slippery feature, softener enhancing hydrophility, wetting agent and with acid to adjust pH between 4.5 and 7.5.
13.A production method according to claim 1 and it is characterized in that steam pressure of the rubber blanket in said sanforizing process is 2.2 bars and 2.4 bars and steam pressure of felt blanket is 4.6 bars to 4.8 bars.
14. A production method according to claim 1 and it is characterized in that the fabric cooled at the said cooling barabans is passed through J-Box unit, then edge openers, rolled at dock rolling unit and conveyed as product for quality control. |
RESISTANT FABRIC PRODUCTION The Related Art
The invention relates to very high resistant denim, gabardine woven cotton fabric production. The invention particularly relates to fabrics of 1500% higher breaking and tearing resistant in comparison to similar weight existing cotton woven fabric in weft and/or warp woven types which can be dyed by means of yarn dying and warp dying technique, and the techniques for production of such fabrics.
Background of the Related Art In the development achieved in this invention a yarn of too high breaking resistance not dyed by means of known methods, known as bare and simple form is dyed according to indigo dying principle and then it is converted into coil and used in woven and knitted fabric sector. In order to provide better understanding of the invention, it will be better to examine the indigo dying technique in brief. Today yarns and fabrics are dyed by use of several different dyes and dying methods. One of the is indigo dying and the yam bundle in the form of rope are passed through several dying baths sequenced consecutively and oxidization of the dye passed onto the yarns is allowed after almost each bath. Indigo dyeing is cubic dyeing type, a considerably different type from normal dyeing. Another difference from other dyes is the low penetration of the dyeing agent to the cellulose yarn fiber. For that reason, dyeing of the yarn is repeated in more than one bath. In other words, the rope passing through the indigo dyeing agent is dyed, is oxidized upon reaching a height and then dyed again. Dyeing agent does not penetrate into the fiber, somehow forms a layer on the outer surface of the fiber. The penetration of the dyeing agent can be increased by means of a caustic processing to be applied before immersing the fiber into dye baths. Ropes in number of 12, 16, 24, 36, 48 can be fed into the dyeing machine at the same time. Dyeing process a continuous process from the beginning up to end of the rope. In other words, dyeing of a lot, that is, dyeing rope from beginning to end takes about an average time of 8 hours. This time period also depends on the lot and the type to be produced as well as the darkness of the desired color.
Today, the yarns are dyed in coils due to indigo dyeing process characteristics. The yams are dyed in two ways with the indigo dyeing;
1- Rope dyeing technique,
2- Warp dyeing technique, In rope dyeing technique the yarns taken from yarn plant in bobbin form are wound in rope winding machines and converted into rope. During this operation about 300 yarns are combined into rope. The yarns converted into rope are unwound after indigo dyeing and the yarns should not be mixed so as to enable winding as warp beam. This is provided by means of cross-wound yarns each 1500 m average length of the rope. The yarns converted into rope are rolled onto rolls and dyed in indigo dyeing plant. The dyed ropes are unwound at unwinding machines and concerted into warp roll and dyed warp yarns are converted directly into woven fabric at weaving looms. The processes realized until this point are. the same at all indigo dyeing plants using rope dyeing system. The indigo yarn dyeing technique known as the most modern technique today is realized through the following stages:
Rope Dyeing System:
360 yarns intended to be dyed in the form of ecru are combined together in one single layer and rope is formed. In order to provide penetration of dyeing agent to each yarn along yam length, the rope is passed through dyeing bath for 6 or 8 times at a sensitive speed. During each passage, the rope is waited sensitively and is subjected to oxidization for coloring and is dried sensitively so as to provide homogenous heat and air flow. Then the yarns forming the rope are separated one by one and formed in warp. Warp Dyeing Method
Each yarn to be dyed is rolled on a winding cylinder or roll just next to each other and in parallel to each other. Then the yarns is passed through dyeing agent baths at 6 or 8 times and various number of air flowing during unrolling from the cylinder at the same speed and tension, and conveyed to another winding cylinder or beam. However, it is not possible to stop during any breaking. The yarn should be resisting enough to withstand the tightness to be applied during the dyeing
process. Speed decrease during production procedures cause non-compensable loss for the business. On the other hand, each stop of the machine causes inevitable loss. Therefore, the waste in such businesses is an essential part of the production and is an inevitable factor that should be anticipated. Warp dyeing process should be continued at the same process value along yarn and the air mixture of the same rate must be ensured in the facility for required constant oxidization.
Loop Dyeing Method
In this method, only one dyeing bath is used instead of 6 or 8 dyeing baths containing thousands of dyeing agent in other methods, and the yams are knotted consecutively to form too large rolls for dyeing. In this method, the ambient minimizes the required conditions for volume and dyeing.
The invention under the patent entitled "group of embodiments for conversion of Indigo dyed yarn into bobbin" numbered TR2000 00373 owned by GAP GUNEYDOGU TEKSTiL SAN. VE TiC. A.S. relates to conversion of ropes dyed with indigo dyeing technique firstly into separator beams for rope weaving, then rolling on the rollers and weaving of the yarns of bobbin in regard to indigo dyeing technique used in the textile sector, and consists of rope pulling unit for rolling of the rope onto the separator, winding unit for winding the beams onto the roller, bobbin unit and weaving unit and therefore relates to realization of forming indigo dyed yams into bobbin and weaving process.
The patent numbered GB 2140834 and entitled "Knitting yarn and knitted fabric" relates to knitting yarn and knitted fabric. The invention is a indigo dyed fabric consisting of knitted cotton yarns wherein the said yarn produced by means of passing of a rope consisting of multiple yarns is twisted randomly or in small groups by means of oxidization in multiple indigo dyeing baths between dye baths and obtaining the indigo dyed yarn having form convenient for knitting.
The patent numbered EP0263223 and entitled "Method and apparatus for the manufacture of cross-wound bobbins comprising indigo dyed weft yarn" relates to a method and apparatus for production of cross-wound bobbins consisting of warp yams. The invention discloses a typical indigo dyeing of cotton yarns twisted from denim starting from spun yams.
Again a patent numbered US 20050186875 and entitled "Firefighter garment outer shell fabric utilizing core-spun dref yarn" relates to a fabric that is particularly well suited for use as the outer shell fabric of the firefighter's garment. The said fabric is preferred 40% Melamine formaldehyde (Basofil) and 60% Para-Aramid (Kevlar) woven of spun yarns and core-spun DREF yarns. The core spun yam includes one or more filament cores selected from a polymer group consisting of PBO, Aramid, Liquid Crystal Polymer (LCP), Carbon and P-84, with or without a fine metallic wire co-core, and a staple sheath blend consisting of one or more fibers selected from a group consisting of Meta-Aramid, Para-Aramid, Copolymide, PBI, PBO, P-84, Carbon, Kynol, PFR Rayon and/or Modacrylic fibers.
The patent numbered US 4829761 and entitled "Continuous filament yarn having spun-like or staple-like character" relates to continuous filament yarn having nonload-bearing fracturable filaments and load-bearing non-fracturable filaments, an elongation-to-break of equal to or less than 180%; yam made from such continuous filament yarn and fractured to have spun-like or staple-like character with the nonload-bearing filaments being variably broken and having free ends either entangled with and/or projecting from the yam bundle; fabric made from the fractured continuous yarn; and process for fracturing the continuous filament yarn.
The patent numbered US4219996 and entitled "Multi-component spun yarn" delates to a multi-component spun yarn. The surface of an open-end spun yarn (staple fibers) having a small degree of twist is covered with a continuous yarn twisted in the same direction. The length of the continuous yarn is greater than that of the open-end spun yarn. Manufacturing method and apparatus are also disclosed. In addition, the related art does not provide centering in a manner allowing cotton fibers winding around the HDPE fiber filament yarn in core (center).
In conclusion, the need for a method for obtaining high resistant fabric and inadequacy of the existing solutions have required development in the related art.
There is a gipe yarn warp and fabric dyed products produced by means of similar process and winding technique in regard to obtain a high resistant fabric.
However, the said products are only resistant in warp direction. The invention of this patent enables achievement of different resistance via different weaving and
double surface weaving technique from yarns produced through high resistant core spun in weft and/or warp direction. It is not only produced as fabric dyeing but also warp dyeing and indigo denim, gabardine woven cotton.
Purpose of the Invention From the status in the related art, the purpose of the invention to eliminate the disadvantages is to ensure high breakage and tearing resistance in weft and/or warp direction of woven fabric types by means of yam dyeing and warp dyeing technique.
Another purpose of the invention is to produce corespun yarn of various size by use of HDPE (High Density PolyEthylene) known as high resistant filament yarn in the core (center) of the yarn forming the fabric and by means of the ring yarn spinning system in a manner cotton fibre is in the outer part of the yarn.
A further purpose of the invention is to obtain denim and gabardine woven cotton fabric by means of using the said yarn as warp in the weaving upon dyeing with indigo dyeing agent in warp dyeing machine.
Another purpose of the invention is to produce denim fabric by means of weaving through passing the HDPE obtained in the core without dyed warp obtained through core spun method and indigo dyed normal cotton together from the sizing to obtain in a single warp and weaving in a manner denim dyed yarns are visible on upper surface of the pure and woven fabric.
In order to prevent permanent mix of yarns forming the rope prepared for indigo dyeing, the cross-yarn warped at every 1500 meters in parties of normal cotton yarn is warped at every 500 meters during formation of rope from yarn being subject of this invention. Another purpose of the invention is that the products are produced fully without dye and the fabric is of the feature enabling dyeing with fabric dyeing or warp yarn dyeing technique.
Fabric was produced by use of corespun HDPE yarn wherein corespun HDPE is in inner surface, cotton in outer surface of double layered denim. Similarly, different sulphure color fabric was produced instead of warp indigo.
Another purpose of the invention is to realize centering process wherein filament yarn of HDPE fiber is in the core (center), covered with cotton fibers.
The structural and characteristics features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations.
Brief Description of Figures
Figure 1 technical settings of standard denim fabric weaving machine,
Figure 2 settings developed for weaving high resistant yarns consisting of HDPE fiber.
DETAILED DESCRIPTION OF THE INVENTION
In order to eliminate the disadvantages existing in the status of the related art, the invention relates to fabrics providing resistance up to 1500% in high breakage and tearing resistance in weft and/or warp direction of the woven fabric types by use of yam dyeing and warp dyeing technique when compared to existing cotton woven fabrics.
The manufacturing of the high resistant yarn with corespun process at the plant hich is the initial stage of the process of the invention is realized as follows; the filament yarn composed of high density polyethylene (HDPE) fiber obtained from the producer firm is subjected to transferring process at the folding machine and the form that can be used at ring yarn machine is obtained. High Density Polyethylene filament yarn converted into small cylinder bobbin is hung onto the hanger part of the ring machine and creel system where the hanger is connected, by means of pulleys specially designed under this invention. Thus, High Density Polyethylene filament yarn is made ready for work at ring yarn machine.
The filament yarn made ready for work at ring yarn machine is hung onto the creels located on the machine together with cord made of 100% cotton. Cotton cord is subjected to gravity as per the density required form the ring yarn machine pulling cylinder. Centering process is realized by means of feeding from rear of output roller and front cot by help of centering apparatus located on the machine. During this operation high density polyethylene filament yarn and cotton fiber
coating around it is provided. The said centering operation is realized in a manner HDPE fiber filament yarn is in the core (center) and cotton fiber coated around it.
In order to help centering process in ring yarn machine apparatus developed under the patent are installed between input drafting roller and medium drafting roller. The said apparatus prevents right-left movement of the cord in pre-drafting zone and helps centering process.
High Strength Yarn Processing:
1) Sizing of High Resi stant Yarn containing HDPE fiber
Two sizing baths are used in regular production. Double baths are used for sizing of the high resistant yarn under the invention. The used sizing is the same as the one used for denim sizing un production and viscosity has been set as 16, refractory as 7. While the drying baraban temperatures in works with 100% cotton yarns is almost always 140 0 C in normal production, it is in range of 110 0 C and
140 0 C and in general 130 0 C for sizing high resistant yarns containing HDPE fibers due to temperature sensitivity of the fibers
In the double layered fabric made by use of high resistant yarn containing corespun HDPE fiber, the high resistant yarn containing HDPE and indigo painted 100% cotton fiber are sized in separate baths where the tension settings of both baths are made separately and the tension is made the same at the point where they combine again. In order to distinguish those two warps at the end of beaming cross-yarn is provided at pre-determined intervals.
2) Con verting the high resistant yarn containing HDPE into rope
The dyeing machine used for denim indigo dyeing is of 24 ropes capacity conventionally. However, 8 to 16 ropes are fed in the process under the invention due to thick Ne of the high resistant corespun yarns consisting of HDPE fiber and not being elastic but mostly 12 ropes are fed for dyeing. For that reason, in case of rope breakage during both rope rolling and rope unrolling of corespun yarns rolled on rollers in 12 ropes during rope rolling, a new and different knotting method has been applied to prevent unknotting during next stages, and thus unknotting of the knots during next stages have been prevented.
Knotting method developed under the Patent: Upon knotting each of breaking ends to other end, the ends are cut between 6 mm to 15 mm but usually at about 10 mm length.
In addition, as the high resistant yarns consisting of HDPE corespun under the scope of the invention being subject of this patent is not elastic, the tension of all wires of the rope have been calculated as a result of experiments in order to prevent problems that might occur during dyeing of rope and thus tension of all wires of the rope is made the same and correct tension value has been calculated.
In addition to these, although the cross-yarns used for guiding purposes during conventional rope rolling are made per each 1500 m, in the process being subject of the patent they are provided between 300 m and 600 m but at every 500 m in general for the yarns used therein, and thus correction of breakage is facilitated and it is targeted to decrease the risk of card blocking during dyeing.
3) Indigo d veing of high resistant yarn containing HDPE fiber Loading of 12 rolls from rope rolling onto creel in indigo is made one full one idle due to the fact that the machine has 24 ropes capacity. In other words, it is loaded onto the creels of 1-3-5-7-9-11-13-15-17-19-21-23 and thus double numbers are left idle and the increase of the distance between ropes is provided by means of skipping one and loading the odd numbers, and prevention of the errors such as blocking in card of the ropes, roll blocking during dyeing is targeted.
Considering the errors such as roll blocking, card blocking despite those precautions during dyeing, the power calculation of the machine driving engine were examined in order to prevent damage by the machine on the rubber, press and oxidization rollers as the resistant of high resistant corespun yarns containing HDPE is too high, and the thermic opening times when the engines are turned off are varied considering the tension values of ropes.
4) Unroll of the high res istant yarn containing HDPE fiber
During unrolling of the high resistant corespun yam ropes containing HDPE arriving rope unrolling part upon dyeing in rope the knotting method used in rope rolling is applied in order to prevent unknot of the knots in the next parts as applied for rope rolling. The ropes of high resistant corespun yarns containing
HDPE fiber are processed at the machines having only zigzag card for rope unrolling and thus damage to comb of the machine and damage to yarns are prevented.
In addition, various experiments were made to find the most convenient tension value so as to prevent stripping of the cotton yarn on the high resistant yarn containing HDPE corespun during rope rolling and also prevent any damage.
Production of high resistant fabric by means of weaving high resistant yarns of HDPE fiber
In order to produce double layered high resistant fabric being subject of the invention, a research to provide warp indigo (or gabardine ) on the upper part and high resistant yams containing HDPE fiber on the lower part was conducted and tension settings of the machine have been made accordingly.
Much easier working conditions were provided in weaving process by help of the changes made under the scope of the patent. In addition to those technical settings the machine normal rpm of 340 weft/minute was decreased to 300 wefts/minute. Weft torsion degree was increased from 6 to 8. Sulzer weaving card was studied as 167.15cmX2 but single card of 334.8 cm should be used. For this type, thickness strength of 3.8 mm hole diameter should be used. Figure 1 shows weaving loom settings for conventional indigo weaving while figure 2 shows machine settings for weaving high resistant yarns containing HDPE fiber.
Finishing work of fabrics woven of high resistant yarn containing HDPE fiber
Before entrance of high resistant fabric being subject of this patent into denim finish machine, it should be cleaned of fibers by help of brushing machine and then burning process for removal of the hairs. Burning flame setting has been decreased slightly uniquely for this type.
Then it has been cooled in cooling barabans. Then it was passed through 10 boms of NaOH solvent of 500 It. Bath compression pressure is 70 psi. While the caustic bom here is checked once per an hour in other process it has been checked once every 15 minutes for this type. In order to prevent fold of the fabric edge in steamer unit coming from pre-treatment a material preventing fold of the fabric edge, called tongs has been used.
Again in order to prevent folding of such type of fabrics of high resistant being subject of this patent, another additional precaution is that the speed of the press engine after steam unit is a bit higher when compared to speed of other press engines. In order to provide better finish of the fabric in finish pad-dry process after washing, it should be dried at drying barabans. It has been subjected to drying for this purpose. The pressure of drying barasan is 4.5 bars. This pressure for other types should not exceed 3.5 bars under normal conditions. The temperature of baraban at this pressure is about 135°C-140 0 C. After drying process, indigo fabrics woven of high resistant yarns containing HDPE fiber are subjected to finishing process. Finishing chemicals include finishing agent providing softness and slippery, softener enhancing hydrophility, wetting agent and acid for pH. (pH range is to be between 4.5 - 7.5). However, the quantity of the softener chemical and wetting agent enhancing hydrophility has been used slightly more for this type when compared to other processes.
The fabric obtained therefrom is subjected to drying process again. Then it has been passed through heated rubber blanket for sanforizing process. During sanforizing the fabric should go into rubber blanket at certain humidity rate for drafting. The steam pressure at rubber blanket is 2.3 bars. Upon drafting process the fabric is subjected to felt blanket for a kind of ironing process. Steam pressure of felt blanket is 4.7 bars. After felt blanketing, the fabric is subjected to cooling barabans as it is highly hot.. After cooling the fabric is passed through J-Box unit and then edge opener and arrived at dock rolling unit and finally conveyed as product for quality control. Breakage and tearing strength values of the four different fabrics constituting subject of this patent in weft and warp direction are given in Table 1.
Table 1
The invention cannot be limited to the representative applications given under this part. Alternative embodiments that might be developed by persons skilled in the related art by use of basic components and/or procedures shall mean violation under the protection scope of the claims part.
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