SYSTEM AND METHOD FOR PROCESSING FIBER

DESCRIPTION

Related Application

[001] This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/771 ,024, filed on February 8, 2006, the disclosure of which is incorporated herein by reference.

Field of the Disclosure

[002] The present disclosure relates to certain aspects of the design and operation of textile operations. More specifically, the present disclosure relates to systems and methods for processing fiber. Background

[003] Textile operations include systems and methods for processing fibers to make them more desirable for the end use of the fibers. For example, textile operations include systems and methods for changing the nature of the fibers, for example, changing the color, the moisture content, and/or the texture of the fibers. In particular, natural fibers, such as wool, silk, and cotton may not occur naturally in a form desirable for the intended end use. Therefore, it may be desirable to process the fibers such that they are more suitable for the intended end use.

[004] An example of a textile operation in which fibers are processed to make them more suitable for their intended end use occurs in a cotton processing system called a "cotton gin." In some cotton processing systems, for example, harvested or "raw" cotton, sometimes in the form of bales, is processed to remove "trash," such as dirt, seeds, seed hulls, plant material, and other objects from the raw cotton fibers prior to processing the cotton fibers into cotton thread and/or fabric. A by-product of such processing is cotton lint, or "mote" cotton, which may become separated from the bulk of the cotton fibers during the cotton ginning process. Typically, such cotton lint or mote cotton may tend to be considered of inferior grade or quality relative to the bulk of the cotton that has been processed, since it may still

have undesirable qualities. For example, the lint may still contain trash, and/or the lint may have an undesirable color, moisture content, and/or texture. Since the cotton lint may be considered of inferior grade or quality, it may be sold only at a price substantially below the market price of the remainder of the processed cotton or it may be discarded entirely. Since a relatively large amount of cotton lint or mote may accumulate during the cotton processing, the value of the cotton lint or mote may represent a potential windfall for the cotton processor if the suitability of the cotton lint or mote for its intended end use can be improved.

[005] Thus, it may be desirable to provide systems and methods for processing fibers in order to render the fibers more suitable for their intended end use. For example, it may be desirable to provide systems and methods for processing fibers to alter at least one of a color characteristic, moisture content, and a texture characteristic of the fibers. Further, it may be desirable to provide systems and methods for processing fibers to alter at least one of color characteristic, moisture content, and texture characteristic of cotton fibers, for example, mote cotton fibers.

[006] The present disclosure may address one or more of these desires.

SUMMARY OF THE DISCLOSURE

[007] Some possible advantages and purposes of the disclosed embodiments will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosed embodiments. Advantages and purposes of the disclosure may be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

[008] According to one aspect, the disclosure includes a system for processing fibers. The system includes a dryer configured to remove moisture from at least a portion of the fibers, and a cleaner configured to remove at least one of dirt, sticks, and seeds from the portion of the fibers. The system further includes a conduit for transferring the portion of the fibers between the dryer and the cleaner, and a treatment system configured to apply chemical to the portion of the fibers. The system for processing fibers is configured to alter at least one of a color

characteristic, moisture content, and a texture characteristic of the portion of the fibers via application of chemical to the portion of the fibers.

[009] According to another aspect, a treatment system for applying chemical to fibers includes a chemical source configured to supply chemical, and an applicator configured to apply chemical to fibers. The treatment system further includes a line configured to provide flow communication between the chemical source and the applicator, and a supply of chemical configured to alter at least one of a color characteristic, moisture content, and a texture characteristic of the fibers.

[010] According to yet another aspect, a method for processing fibers to alter at least one of a color characteristic, moisture content, and a texture characteristic of the fibers includes removing an amount of moisture from at least a portion of the fibers. The method further includes removing at least one of dirt, sticks, and seeds from the portion of the fibers, and applying chemical to the portion of the fibers, wherein applying chemical to the portion of the fibers comprises applying at least one of bleach and dye to the portion of the fibers.

[011] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and, together with the description, serve to explain some principle of the invention. In the drawings,

[013] Fig. 1 Is a schematic elevation view of an exemplary embodiment of a fiber processing system; and

[014] Fig 2 is a schematic elevation view of an exemplary embodiment of a fiber processing system.

DESCRIPTION OF EMBODIMENTS

[015] Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[016] Fig. 1 schematically depicts an exemplary embodiment of a fiber processing system 10 configured, for example, to process fibers in association with a textile operation. Fiber processing system 10 is configured to process fibers, such as, for example, cotton fibers in a cotton ginning operation and/or a moting operation. According to some embodiments, fiber processing system 10 may be configured to convert fibers received in a form generally considered unsuitable for their intended end use to fibers more suitable for their intended use, for example, for use in textile operations. For example, fiber processing system 10 may be configured to receive harvested cotton in bale form, including trash, such as sticks, seeds, seed hulls, dirt, etc., and remove at least a portion of the trash for use in further textile operations, such as thread and/or fabric manufacturing.

[017] According to some embodiments, fiber processing system 10 may include a fiber unloading area 12, one or more dryers 14, one or more fiber cleaners 16, one or more cleaners 18 (e.g., ginsaw cleaners), one or more lint cleaners 20, a battery condenser 22, and/or a bale press 24. Fiber processing system 10 may further include a fiber conveyance system 26, including a series of conduits 28 for conveying the fiber to one or more of the portions of fiber processing system 10. Fiber conveyance system 26 may include a propulsion unit 30 and a temperature control unit 32. Upon exit of fiber processing system 10, the fibers may be in a more suitable form for further textile operations, such as, for example, the production of thread and/or fabric formed at least partially from the fibers.

[018] Exemplary fiber processing system schematically depicted in Fig. 1 includes components generally consistent with a cotton gin for processing cotton fibers. One or more of the components shown in Fig. 1 may not necessarily be included in fiber processing system 10, and fiber processing system 10 may be configured to process fibers other than cotton fibers. For example, Fig. 2 schematically depicts an exemplary fiber processing system 10 that does not include a cleaner 18 (e.g., a ginsaw cleaner), and fiber processing system 10 shown in Fig. 2 may be used to process fibers other than cotton fibers, such as, for example, silk fibers, wool fibers, and/or any other types of fibers whose characteristics might be improved by cleaning and/or treatment.

[019] According to some embodiments, fiber unloading area 12 may be, for example, a device configured to break apart large bales of harvested fibers, such as

cotton. For example, fiber unloading area 12 may be a module feeder or any other device for converting fibers into a form for cleaning. A module feeder may be, for example, configured to rip apart bales of harvested cotton into smaller portions and/or separate large debris such as sticks from the cotton.

[020] Following processing in unloading area 12, the fibers may be conveyed to dryer 14 via conduit 28 and propulsion unit 30. For example, propulsion unit 30 may be a blower (i.e., a fan) or series of blowers arranged throughout fiber processing system 10, which are configured to blow the broken apart fibers through conduits 28. Conveyance system 26 may also include temperature control unit 32, such as, for example, a heater. According to some embodiments, fiber processing system 10 may be a closed-loop system, such as, for example, the closed-loop system disclosed in commonly-assigned U.S. Patent No. 6,557,213, the disclosure of which is incorporated herein by reference.

[021] According to some embodiments, dryer 14 may be, for example, a hot shelf tower dryer or any other fiber dryer known to those having ordinary skill in the art. Dryer 14 is configured to adjust the moisture content of the fibers, for example, to facilitate cleaning and/or coloring of the fibers. For example, one or more temperature control units 32 may be provided to reduce or eliminate moisture in the fibers. Temperature control unit 32 may be, for example, a heater (e.g., a burner), and propulsion unit 30 may serve to convey hot air generated by a burner to dryer 14.

[022] After adjusting the moisture content of the fiber via dryer 14, at least a portion of the fibers may be propelled via a conduit 28 to fiber cleaner 16. Fiber cleaner 16 is configured to remove trash, such as, for example, sticks, seeds/seed pods, and/or other debris, from the fibers. Trash may be removed from fiber cleaner 16 via, for example, an extractor 34, for disposal. Fiber cleaner 16 may be any type of cleaner known to those having ordinary skill in the art, such as, for example, the fiber cleaner disclosed in commonly-assigned U.S. Patent 6,038,741, the disclosure of which is incorporated herein by reference.

[023] Fibers exiting fiber cleaner 16 may be conveyed to cleaner 18 (e.g., a ginsaw cleaner) via conduit 28. Cleaner 18 may be configured to remove additional trash, such as sticks and/or debris from the fibers.

[024] According to some embodiments, fiber processing system 10 may include one or more lint cleaners 20. Lint cleaner(s) 20 are configured to remove small trash and/or debris (e.g., trash smaller in size relative to the size of trash removed by fiber cleaner 16) from the fibers. Fibers may be conveyed to lint cleaner(s) 20 via a conduit 28 and propulsion unit 30. For example, propulsion unit 30 may include a number of blowers provided at different locations of fiber processing system 10 to convey the fibers from one location to another.

[025] Fiber processing system 10 may further include a battery condenser 22, and fibers may be conveyed from lint cleaner(s) 20 to battery condenser 22 via a conduit 28. Battery condenser 22 is configured to remove air from the fibers (e.g., cotton fibers), so that the fibers may be formed into a batt (e.g., a cotton batt), which may be conveyed down a lint slide 36 into bale press 24. Bale press 24 is configured to form the fiber batts into bales.

[026] According to some embodiments, fiber processing system 10 may include a chemical treatment system 38. Chemical treatment system 38 may be configured to alter characteristics of the fibers in association with fiber processing system 10. For example, chemical treatment system 38 may be configured to alter the color, moisture content, and/or the texture of the fibers. For example, chemical treatment system 38 may enhance the whiteness and/or brightness of the fibers, and/or improve the softness of the fibers (e.g., cotton fibers and/or mote cotton) to render them more desirable.

[027] According to some embodiments, chemical treatment system 38 may include one or more chemical sources 40, one or more controllers 41 configured to control operation of chemical treatment system 38, one or more conveyance lines 42, and one or more applicators 44 for applying one or more chemicals to the fibers as they are conveyed through fiber processing system 10. The applicators 44 may be in flow communication with one or more of the chemical sources 40 via conveyance lines 42, and controller(s) 41 may be configured to control distribution and/or the amount of chemical flow to one or more of applicators 44. According to some embodiments, controllers) 41 may be configured to be operated manually and/or automatically, for example, via electronic control (e.g., digital and/or analog electronic control).

[028] Chemical sources 40 may include containers located in the vicinity of fiber processing system 10 (e.g., barrels and/or drums of chemical). According to some embodiments, chemical sources 40 may include containers the of chemical and/or lines that serve to supply chemicals from a source located remotely from fiber processing system 10, such as, for example, container's located outside a facility in which fiber processing system 10 is located (e.g., containers located adjacent the facility and/or containers associated with a railway).

[029] According to some embodiments, chemical treatment system 38 may include any chemical, including, for example, one or more chemicals configured to alter the color characteristic and/or the texture characteristic of the fibers. For example, the chemical may be configured to whiten and/or brighten the color characteristic, and/or to change the hue and/or the shade of the fibers. The chemical may include one or more of bleaches, dyes, water, and oils, for example, hydrogen peroxide (H ₂ O ₂ ). According to some embodiments, chemical treatment system 38 may result in, for example, removal of a majority (e.g., almost all) of the seeds and/or dark specs from the fibers, such as, for example, mote cotton fibers. The chemical may be in one or more of solid, liquid, and gaseous form.

[030] According to some embodiments in which the chemical includes, for example, H ₂ O ₂ , exemplary systems and methods for processing fibers may provide a substantially environmentally friendly alternative to other processing systems and methods. In particular, since H ₂ O ₂ , for example, includes only hydrogen and oxygen, by-products of its use may be limited to hydrogen and oxygen, which do not provide undesirable emissions sometimes associated with some other chemicals, such as, for example, chemicals containing carbon, chlorine, and/or fluorine.

[031] According to some embodiments, the chemical may be applied in differing concentrations. For example, H ₂ O ₂ may applied in dilutions ranging from about 1.0% to about 90%, for example, about 1.6%, about 6%, about 35%, about 50%, or about 75%. According to some embodiments, the chemical may be diluted with, for example, water. Such dilution may occur prior to application of the chemical to the fibers and/or during application of the chemical to the fibers. For example, chemical having a particular concentration may be diluted prior to entering the system 10. Alternatively, or in addition, dilution may occur by applying the chemical with one or more applicators and applying, for example, water with one or more

additional applicators, to achieve a desired effective dilution of the chemical applied to the fibers.

[032] According to some embodiments, the amount and/or dilution of the chemical applied to the fibers may be a function of the fibers being processed. For example, it may be desirable to apply more or less chemical to some fibers and/or differing concentrations of chemical to some fibers, depending on the amount of trash in the fibers and/or the type of fibers.

[033] Some fibers (e.g., cotton fibers) may be able to accept or absorb only a limited amount of chemical during each application of chemical. According to some embodiments, fiber processing system 10 may be configured for application of chemical at more than one time and/or location during a textile processing operation. For example, fibers may be dried at various locations before, during, and/or after undergoing processing via fiber processing system 10 to reduce the moisture content of the fibers, which may condition the fibers to receive more chemical (i.e., as moisture is removed from the fibers (e.g., cotton fibers), more chemical may be applied to the fibers). According to some embodiments, the fibers may be exposed to the chemical (e.g., H2O2) in a vat of the chemical as an alternative (or in addition to) applying the chemical via other techniques and/or at other locations.

[034] According to some embodiments, chemical may be applied at different locations of fiber processing system 10. According to some embodiments, chemical may be applied at different location of a cotton gin process and/or a moting process (i.e., a post-ginning process). For example, "mote" is cotton, such as, for example, lint cotton, etc., that may be generated during a cotton ginning process that is generally discarded. During a cotton ginning process, for example, lint cotton and generally less desirable cotton is produced as a by-product of the cotton ginning process. Mote cotton may contain, for example, trash and seeds/seed hulls, which may render the mote cotton generally less desirable by virtue of its low grade (i.e., the lowest grade cotton). Under normal circumstances, mote cotton might have a yield of about 50% and sell for about $0.05/lb. According to some embodiments, chemical treatment system 38 may result in enhancing mote cotton, such that it may sell, for example, for about $0.57/lb.

[035] According to some embodiments, chemical treatment system 38 may be configured to apply chemical to the fibers at one or more of many different

locations of fiber processing system 10. For example, chemical treatment system 38 may be configured to apply chemical at only one location of fiber processing system 10 (e.g., at a location immediately prior to battery condenser 22). According to some embodiments, chemical treatment system 38 is configured to apply chemical to the fibers at more than one location of fiber processing system 10. For example, chemical treatment system 38 may include applicators 44 located at one or more of the following locations: between unloading area 12 and dryer 14, at dryer 14 (e.g., at one or more locations within dryer 14), between dryer 14 and cleaner 16, between cleaner 16 and saw cleaner 18, between saw cleaner 18 and lint cleaner 20, between two lint cleaners 20, between lint cleaner 20 and battery condenser 22, and between battery condenser 22 and bale press 24. According to some embodiments, applicator(s) 44 may be located before unloading area 12 and/or after bale press 24.

[036] Applicator(s) 44 may be of any type configured to supply chemical to the fibers. For example, applicator(s) 44 may be in the form of any one of the following devices: one or more sprayers, brushes, nozzles, wipers, dispensers, and vats of chemical. For example, one or more applicators 44 may be configured to apply the chemical via, for example, an atomized spray.

[037] Traditionally, during textile processing, fibers are transported from one operation to another by various devices/methods, which include conveyors, belts, gravity, and air propulsion. Chemical treatment system 38 may be configured to apply various chemical and/or liquids to the fibers. According to some embodiments, chemical may be applied, for example, by applicators 44, such as spraying units, which direct chemical into the air that carries the fibers. According to some embodiments, the applicator(s) 44 may be configured to calibrate the amount of chemical being applied to the fibers. The amount of chemical and/or the type of chemical applied, where the chemical is applied, and the method of application may depend, for example, on the various degrees of grade and/or character of the fibers, including color, which may be desired by the end user.

[038] According to some embodiments, the amount of chemical applied during processing of the fibers could reach, for example, up to about 10 percent or more of the weight of the fibers, and it may be desirable to process the fibers such that they have a moisture content low enough to accept the chemical and/or keep the fibers (e.g., baled fibers) in a moisture content range acceptable to the end user.

[039] According to some embodiments, the moisture content of the fibers may be controlled. For example, the fibers my be dried via, for example, dryers 14 and/or any drying systems known to those having ordinary skill in the art, such as a closed-loop system at least similar to those described previously herein. Other drying systems could be used to obtain the same or similar results.

[040] According to some embodiments, chemical may be applied before drying and/or after drying, and/or before the cleaners and/or after the cleaners. For example, fiber processing system 10 may include more than one set of the exemplary components described previously herein. The number of sets of components used may depend on, for example, the desired characteristic(s) of the fibers. For example, each set of components (e.g., dryer 14 and cleaner(s)) may be configured to reduce the moisture content of the fibers by an amount roughly corresponding to an amount of moisture content that will be added by virtue of the application of chemical, as desired for safe storage of the fiber. According to some embodiments of fiber processing system 10, it may not be necessary to use cleaner(s). Rather, it may be possible to use one or more dryers 14 without any cleaners.

[041] According to some embodiments, chemical may be applied to the fibers at lint slide 36 (i.e., after battery condenser 22 and prior to bale press 24). For example, applicator(s) 44 may include one or more sprayers configured to direct a spray across the fibers prior to bale press 24. According to some embodiments, fiber processing system 10 may include one or more dryers 14 located prior to bale press 24 to reduce the moisture content of the fibers prior to bale press 24, for example, to reduce to the moisture content of the fibers prior to applying chemical between battery condenser 22 and bale press 24.

[042] According to some embodiments of fiber processing system 10, chemical applied to the fibers may result in bleaching, whitening, and/or enhancing the color of the fibers (e.g., cotton fibers) during textile operations, such as, for example, during a fiber processing operation (e.g., during a cotton ginning and/or moting process). For example, according to some embodiments, fiber processing system 10 may be configured to reduce a pre-application moisture content of the fibers down to a level such that the fibers (e.g., cotton) are capable of accepting chemical and/or other fluids desired to be applied to the fibers, which, in turn, may

return the fibers back to their pre-applicatioπ moisture content. According to some embodiments, such a process may be repeated a number of times, for example, until the fibers have obtained a desired color characteristic and/or texture characteristic.

[043] For example, the moisture content of fibers entering fiber processing system 10 may be about 8% (e.g., 8% by weight). It may be estimated that in order to obtain a desired color and/or texture characteristic of the fibers, about 25 lbs. of chemical (e.g., about 0.05% of chemical) should be applied to the fibers. In order approximately maintain the 8% moisture content of the fibers upon the addition of 25 lbs. of chemical, it may be desirable to lower the moisture content of the fibers to about 3% prior to application of the chemical. Upon application of 25 lbs. of chemical, the moisture content of the fibers may return to approximately 8%. If further application of chemical is desired, for example, in order to further manipulate the color and/or texture characteristics (based on, for example, color and/or foreign matter content), the moisture content of the fibers may be altered, for example, to reduce the moisture content of the fibers to a desired level, which permits fibers to accept a desired amount of additional chemical application (e.g., including application of chemical, water, and/or oils) while substantially achieving a desired moisture content of the fibers following application of the chemical.

[044] According to some embodiments, fibers processed by the exemplary systems and methods may become whiter, brighter, and/or softer to the touch after processing. For example, cotton fibers processed by the exemplary systems and methods may become whiter, brighter, and/or softer to the touch than unprocessed cotton fibers or cotton fibers processed using conventional methods. For example, cotton fibers processed according to the exemplary systems and methods may exhibit softer "hand" (or feel to the touch) than cotton fibers that have been subjected to conventional vat bleaching techniques.

[045] Some embodiments of fiber processing system 10 may not necessarily include each of the components described previously herein. Further, some embodiments of fiber processing system 10 may include components not described herein. According to some embodiments, fiber processing system 10 and associated methods may be used in association with any textile operation relating to any types of fibers. In particular, some embodiments of fiber processing system 10 are not necessarily limited to use in relation to cotton ginning and/or mote cotton

operations. According to some embodiments, the systems and methods may be used to process natural fibers (e.g., cotton, wool, and/or silk), combinations of different types of natural fibers (e.g., at least one of cotton, wool, and silk fibers), synthetic fibers, and combinations of natural and synthetic fibers.

[046] It will be apparent to those skilled in the art that various modifications and variations can be made to the system of the present invention and in construction of this system without departing from the scope or spirit of the invention, as other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.