Fabric treatment apparatus and method

Abstract

An apparatus for treatment of fabric, and including a fabric supply for supplying a length of dry fabric. A plurality of rolls having fabric-altering surface elements thereon is positioned in an upstream-to-downstream flow path for receiving the length of fabric across the surface elements thereof from an upstream fabric supply assembly to a downstream fabric take-up assembly. At least some of the plurality of rolls have drive means for positively rotating the rolls. The take-up assembly pulls the length of dry fabric off of the fabric supply assembly and through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

Description

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0001] This invention relates to a fabric treatment apparatus and method. This form of treatment is generally referred to as “converting” and refers generally to processes performed on greige woven fabrics after fabric formation to render the fabric suitable for a particular end use. Most of these processes have traditionally involved wetting and washing the fabric in water and certain chemicals, such as acids, enzymes, surfactants, soaps and other substances to affect the appearance or feel of the fabric. In many cases, the treatment is intended to imitate natural wear and thereby give the fabric a used or worn look. The apparatus and method is particularly useful in processing fabrics made in whole or in part from natural, cellulosic fibers.

[0002] Most such converting processes require forming a long length of woven fabric into an endless loop, that is then cycled through the processing machine a specified number of times. When the fabric is wet-processed, substantial time and heat is required to dry the fabric after processing. Drying the fabric often results in a rough, boardy feel which must then be removed by further processing.

[0003] Through experimentation it has been determined that controlled impact of the fabric by various shapes and edges as the fabric passes through an apparatus will impart surface characteristics to the fabric without wetting. The present invention provides a method and apparatus for dry-processing fabric to provide a predetermined feel and surface appearance to the fabric. The treatment enhances the drape of the fabric and stabilizes the fabric in advance of fabrication of the fabric into a particular end use. Such fabrics are suitable for cut-and-sew operations which convert the fabric into garments and household linens such as sheets, pillow cases and the like. The apparatus is easily modified to alter the characteristics imparted to the fabric.

SUMMARY OF THE INVENTION

[0004] Therefore, it is an object of the invention to provide an apparatus and method for converting fabrics.

[0005] It is another object of the invention to provide an apparatus and method for converting fabrics by surface treatment without wetting the fabric.

[0006] It is another object of the invention to provide an apparatus and method for converting fabrics by surface treatment with only one pass of the fabric through the apparatus.

[0007] It is another object of the invention to provide an apparatus and method for converting fabrics by a dry surface treatment that is easily and quickly variable to alter the characteristics of the converted fabric.

[0008] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing an apparatus for treatment of fabric, and comprising a fabric supply assembly for supplying a length of dry fabric. A plurality of rolls having fabric-altering surface elements thereon is positioned in an upstream-to-downstream flow path for receiving the length of fabric across the surface elements thereof from the upstream fabric supply assembly to a downstream fabric take-up assembly. At least some of the plurality of rolls are positively driven, and a take-up assembly pulls the length of dry fabric off of the supply assembly and through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

[0009] According to one preferred embodiment of the invention, the take-up assembly includes a variable speed motor for pulling fabric through the apparatus at a variable predetermined constant rate.

[0010] According to another preferred embodiment of the invention, the drive means of the rolls are reversible for rotating the rolls in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric.

[0011] According to yet another preferred embodiment of the invention, the drive means are individual to each drivable roll for selectively rotating a roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric without regard to the direction of movement of any other roll.

[0012] According to yet another preferred embodiment of the invention, the fabric supply assembly includes brake remains for applying a predetermined resistance to the movement of the fabric through the flow path to reduce wrinkling of the fabric and maintain contact between the fabric and the rolls.

[0013] According to yet another preferred embodiment of the invention, the surface elements are selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons.

[0014] According to yet another preferred embodiment of the invention, each of the outwardly-projecting edge members defines a wavy surface edge.

[0015] According to yet another preferred embodiment of the invention, each of the outwardly-projecting edge members defines a wavy surface edge wherein the wavy surface edge of each edge member is out-of-phase with the surface edge of any adjacent edge member.

[0016] According to yet another preferred embodiment of the invention, the edge members are paired to define a v-shape in cross-section.

[0017] According to yet another preferred embodiment of the invention, an apparatus for treatment of fabric is provided, and comprises a fabric supply assembly for supplying a length of dry fabric and a plurality of rolls having fabric-altering surface elements thereon positioned in an upstream-to-downstream flow path for receiving the length of dry fabric across the surface elements from an upstream fabric supply assembly to a downstream fabric take-up assembly. The surface elements are selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons. Drive means are provided for positively rotating at least some of the plurality of rolls. The drive means are individual to each drivable roll for selectively rotating the roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric without regard to the direction of movement of any other treatment roll. The take-up assembly pulls the length of fabric off of the fabric supply assembly and through the flow path against the surface elements of the plurality of treatment rolls in only a single pass and onto the take-up assembly.

[0018] According to yet another preferred embodiment of the invention, a method according to the invention comprises the steps of providing a plurality of rolls having fabric-altering surface elements thereon. The rolls are positioned in an upstream-to-downstream flow path for receiving a length of fabric across the surface elements thereof from an upstream fabric supply assembly to a downstream fabric take-up assembly. Drive means are provided for at least some of the rolls for positively rotating the rolls. A length of dry fabric is pulled off of the take-up assembly, through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

[0019] According to yet another preferred embodiment of the invention, the step of providing drive means comprises the step of providing a variable speed motor for pulling fabric through the apparatus at a variable predetermined constant rate.

[0020] According to yet another preferred embodiment of the invention, the method includes the step of selectively rotating the rolls in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric.

[0021] According to yet another preferred embodiment of the invention, the method includes the step of selectively rotating a roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric without regard to the direction of movement of any other roll.

[0022] According to yet another preferred embodiment of the invention, the method includes the step of applying a predetermined resistance to the movement of the fabric through the flow path to reduce wrinkling of the fabric and maintain contact between the fabric and the rolls.

[0023] According to yet another preferred embodiment of the invention, the surface elements are selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons.

[0024] According to yet another preferred embodiment of the invention, each of the outwardly-projecting edge members defines a wavy surface edge.

[0025] According to yet another preferred embodiment of the invention, each of the outwardly-projecting edge members defines a wavy surface edge wherein the wavy surface edge of each edge member is out-of-phase with the surface edge of any adjacent edge member.

[0026] According to yet another preferred embodiment of the invention, the edge members are paired to define a v-shape in cross-section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:

[0028] FIG. 1 is a flow diagram of a fabric treating apparatus according to an embodiment of the invention;

[0029] FIG. 2 is a flow diagram of the fabric treating apparatus according to FIG. 1, and set up for processing a light cotton upholstery fabric;

[0030] FIG. 3 is a flow diagram of the fabric treating apparatus according to FIG. 1, and set up for processing a denim fabric;

[0031] FIG. 4 is a schematic representation of a roll having ribbon scroll elements thereon;

[0032] FIG. 5 is a schematic representation of a roll having spiral flutes thereon;

[0033] FIG. 6 is a schematic representation of a roll having outwardly projecting blades with wavy edges thereon;

[0034] FIG. 7 is a schematic representation of a roll having chain thereon;

[0035] FIG. 8 is a schematic representation of a roll having brass buttons thereon; and

[0036] FIG. 9 is a schematic representation of a roll having grit thereon.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

[0037] Referring now specifically to the drawings, a fabric treating apparatus according to the present invention is illustrated in FIGS. 1, 2 and 3, and shown generally at reference numeral 10. The fabric treating apparatus 10 comprises a frame 11 which mounts rolls across which fabric to be processed is passed, as described below. The frame 11 according to one embodiment of the invention is 8 ft. wide and accepts rolls which will accommodate and process fabric up to 84 in. wide. Other widths are, of course, possible.

[0038] A roll of fabric “F” is mounted on a supply mandrel 12 and fed through top and bottom supply rolls 13 and 14. The fabric 11 is fed in open width and is generally sewn to a piece of waste fabric that is used to feed the fabric “F” into the apparatus 10 and to establish proper running conditions before the actual fabric treatment process begins. The fabric “F” is processed in dry form. As used herein, “dry” means a fabric which contains only ambient humidity or only such additional humidity as is necessary to optimize processing without the necessity of a subsequent drying process, as would be necessary by saturating the fabric with water.

[0039] Preferably, the top roll 13 includes a brake assembly 15 which imparts drag to the supply rolls 13, 14. By retarding rotation of the supply rolls 13, 14, tension sufficient to prevent or reduce wrinkling and insure contact between the fabric and the treatment rolls is provided. The brake assembly 15 may be a drum brake powered by a pneumatic pressure actuator.

[0040] At least one of the supply rolls 13, 14 is covered with grit to reduce lateral movement of the fabric “F” and consequent wrinkling or skewing as the fabric “F” is fed downstream.

[0041] Idler rolls 18, 19, 20 and 21 define the general upstream-to-downstream flow path of the fabric. These idler rolls have polished surfaces and position the fabric to be properly fed to treatment rolls 25, 26, 27 and 28.

[0042] Treatment rolls 25, 26, 27 and 28 are carried for rotation by frame 11 in suitable bearings and are preferably driven by individual drive motors 25A, 26A, 27A and 28A. Alternatively, some or all of the rolls 25, 26, 27 and 28 can be driven through chain or gear drives from a single or multiple motors. Motors 25A, 26A, 27A and 28A are variable speed, reversing direction motors.

[0043] As described below, each of the rolls 25, 26, 27 and 28 are provided with predetermined surface treatment elements based on the finish to be applied to the fabric surface. Fabric treatment may take place by passing the fabric over one, less than all, or all of the treatment rolls 25, 26, 27 and 28. Likewise, the rolls 25, 26, 27 and/or 28 may be changed to alter the type of surface treatment elements or to vary the order in which the fabric engages a particular surface treatment element.

[0044] The processed fabric “F” may be rolled onto a take-up roll 30 by a pair of feed rolls 31, 32 driven by a motor 33. Motor 33 is preferably a 2.5 HP motor connected to a variable speed drive which permits the fabric “F” to be fed at varying rates of between approximately 3-30 yd/min. Alternatively, the fabric “F” may be fed by the feed rolls 31, 32 into a container for later retrieval. The apparatus 10 and associated method differ from many systems whereby the fabric must be formed into a loop and passed multiple times through the processing areas of the equipment.

[0045] Referring now to FIGS. 4-8, the surface elements carried by the treatment rolls 25-28 are illustrated. For purposes of illustration only, the surface elements are shown in a particular arrangement. However, the order of the surface elements in the flow path may vary, some surface elements may not be used with particular fabrics, and some surface elements may be used on multiple rolls.

[0046] FIG. 4 illustrates the roll 25 that is covered with ribbon scroll wire 40 that is spiraled in spaced-apart relation around the surface of the roll 25. The wire 40 is spiraled symmetrically from the center to opposite ends of roll 25 with the spiral in the direction whereby the fabric is maintained in a taut condition by the movement of the spiraled wire 40 as it passes over the roll 25. The diameter of the wire 40 and the spacing between adjacent wraps may be vary, a typical diameter being ⅛ in. with 1 in. spacings between adjacent wraps. The surface of the wire 40 is relatively smooth, and the principal function of this roll is to maintain the fabric “F” at its full width without wrinkles or skewing.

[0047] FIG. 5 illustrates a spiraled high rib flute 41 welded to the surface of the treatment roll 26. The flute 41 is spiraled symmetrically from the center to opposite ends of roll 26 with the spiral in the direction whereby the fabric is maintained in a taut condition by the movement of the spiraled flute 41 as it passes over the roll 26. The pitch of the spiral is such that the flutes will exert a lateral brushing motion to the surface of the fabric “F” which begins the process of softening and breaking the stiffness of the fabric “F.” The spacing between adjacent wraps of the flute 41 may be vary, a typical spacing being approximately 4 in. between adjacent wraps.

[0048] Referring now to FIG. 6, roll 27 is provided with four pairs of blades 42 which extend outwardly in a v-shaped configuration laterally along the length of roll 27. These blades may be straight or, as shown, provided with a undulating outer edge which appears wavy and which will thus engage the fabric “F” with different force at different positions along its width. The undulations in the blades 42 are offset relative to each other so that all of the blades 42 do not engage the fabric with the same impact at the same position along the width of the fabric. This provides a randomized abrading treatment to the surface of the fabric which assists in breaking down the starch component of the fibers and thus contributes to a desirable softening of the fabric “F.”

[0049] Referring now to FIG. 7, roll 28 is covered with a length of chain 44 welded to the surface in a spiral configuration. The chain 44 is spiraled symmetrically from the center to opposite ends of roll 28 with the spiral in the direction whereby the fabric is maintained in a taut condition by the movement of the spiraled chain 44 as it passes over the roll 28. The size and type of chain can vary widely depending on the desired effect to be achieved, and the spacing between adjacent wraps may vary, a typical spacing between adjacent wraps being 2 in. The surfaces of the chain 44 are of varying heights and orientations relative to the roll 28 and the direction of travel of the fabric “F”, and thereby imparts vigorous, random impacts to the fabric “F” as it passes over the roll 28.

[0050] Referring now to FIG. 8, a roll 50 is shown and illustrates another type of surface treatment element which may be used in the apparatus 10 in place of or along with rolls of the type discussed above. Roll 50 is covered with an array of raised brass buttons 51, which, for example, are ⅝ in. in diameter and extend upwardly ⅜ in. above the adjacent surface of the roll 50. Alternatively, buttons of differing diameters and heights may be applied.

[0051] As noted above, either roll 13 or 14, roll 13 shown in FIG. 9, is covered with a sheet having grit 47 adhered thereto. However, a roll having grit on the surface may be used in place of one or more of the rolls 25, 26, 27, 28 to give the surface of the fabric “F” a napped or “sanded” look.

[0052] Referring again to FIGS. 1, 2 and 3, each of the rolls 25, 26, 27, and 28, being driven by variable speed, reversing motors 25A, 26A, 27A, and 28A, may be driven at a surface speed different from the rate of travel of fabric “F” through the apparatus 10, and in an opposite direction. This enables substantially different relative rates of movement between the fabric “F” and the various surfaces on the rolls 25, 26, 27, and 28.

[0053] FIG. 2 illustrates the apparatus 10 configured to process a light cotton upholstery fabric. Fabric “F” is pulled by the take-up rolls 31, 32 off of the supply roll positioned on supply mandrel 12. The fabric is passed behind idler roll 18 and against treatment roller 25, that is set up to rotate in the opposite direction to the direction of travel of the fabric “F.” The fabric “F” then passes under idler roller 19, over treatment roller 26, under idler roller 20, over treatment roller 27, under treatment roller 28, past idler roller 21 and then through the take-up rollers 31, 32.

[0054] The treatment rollers 26, 27 and 28 rotate in the same direction of travel as the fabric “F”, and are driven by respective motors 26A, 27A, and 28A at a surface speed different from the rate of travel of the fabric “F”, thus providing a surface treatment to the fabric “F.” The fabric “F” is passed through the apparatus 10 only once, and either the face or reverse side of the fabric “F” may be oriented directly against the treatment rollers 25, 26 27 and 28. Alternatively, the fabric “F” may be passed through the apparatus 10 with both sides being engaged by different ones of the rollers 25, 26 27 and 28. In each case, the rollers 25, 26, 27 and 28 are configured as illustrated and described with reference to FIGS. 4, 5, 6 and 7.

[0055] FIG. 3 illustrates the apparatus 10 configured to process a denim fabric “F”. Fabric “F” is pulled by the take-up rolls 31, 32 off of the supply roll positioned on supply mandrel 12. The fabric “F” is passed behind idler roll 18 and against treatment roller 25, that is set up to rotate in the opposite direction to the direction of travel of the fabric “F.” The fabric “F” then passes under idler roller 19, over treatment roller 26, under idler roller 20, over treatment roller 27, under idler roller 21 and then through the take-up rollers 31, 32.

[0056] The treatment rollers 26 and 27 rotate in the same direction of travel as the fabric “F”, and are driven by respective motors 26A and 27A at a surface speed different from the rate of travel of the fabric “F”, thus providing a surface treatment to the fabric “F.” The fabric “F” is passed through the apparatus 10 only once, and either the face or reverse side of the fabric “F” may be oriented directly against the treatment rollers 25, 26 and 27.

[0057] A fabric treating apparatus is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.

Claims

1. An apparatus for treatment of fabric, and comprising:

(a) an upstream fabric supply assembly for supplying a length of dry fabric;

(b) a plurality of rolls having fabric-altering surface elements thereon positioned in an upstream-to-downstream flow path for receiving the length of fabric across the surface elements thereof from the fabric supply assembly, at least some of the plurality of rolls having drive means for positively rotating the rolls; and

(c) a take-up assembly for pulling the length of dry fabric off of the fabric supply assembly and through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

2. An apparatus according to claim 1, wherein said take-up assembly includes a variable speed motor for pulling fabric through the apparatus at a variable predetermined constant rate.

3. An apparatus according to claim 1, wherein the drive means of the rolls are reversible for rotating the rolls in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric.

4. An apparatus according to claim 1, wherein said drive means are individual to each drivable roll for selectively rotating a roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric independent of the direction of movement of any other roll.

5. An apparatus according to claim 1, wherein said fabric supply assembly includes brake means for applying a predetermined resistance to the movement of the fabric through the flow path to reduce wrinkling of the fabric and maintain contact between the fabric and the rolls.

6. An apparatus according to claim 1, wherein said surface elements are selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons.

7. An apparatus according to claim 6, wherein each said outwardly-projecting edge member defines a wavy surface edge.

8. An apparatus according to claim 6, wherein each said outwardly-projecting edge member defines a wavy surface edge wherein the wavy surface edge of each edge member is out-of-phase with the surface edge of any adjacent edge member.

9. An apparatus according to claim 6, wherein said edge members are paired to define a v-shape in cross-section.

10. An apparatus for treatment of fabric, comprising:

(a) an upstream fabric supply assembly for supplying a length of dry fabric;

(b) a plurality of rolls having fabric-altering surface elements thereon positioned in an upstream-to-downstream flow path for receiving the length of dry fabric across the surface elements from the fabric supply assembly;

(c) the surface elements selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons;

(d) drive means for positively rotating at least some of the plurality of the rolls, the drive means being individual to each drivable roll for selectively rotating the roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric without independent of the direction of movement of any other roll; and

(e) a take-up assembly for pulling the length of fabric off of the fabric supply assembly and through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

11. A method of treating fabric, and comprising the steps of:

(a) providing a plurality of rolls having fabric-altering surface elements thereon and positioned in an upstream-to-downstream flow path for receiving a length of fabric across the surface elements thereof from an upstream fabric supply assembly to a downstream fabric take-up assembly;

(b) providing drive means for at least some of the rolls for positively rotating the rolls; and

(c) pulling a length of dry fabric off of the fabric supply assembly, through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

12. A method according to claim 11, wherein the step of providing drive means comprises the step of providing a variable speed motor for pulling fabric at a variable predetermined constant rate.

13. A method according to claim 11, and including the step of selectively rotating the rolls in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric.

14. A method according to claim 11, and including the step of selectively rotating a roll in either the direction of movement of the fabric or in opposition to the direction of movement of the fabric independent of the direction of movement of any other roll.

15. A method according to claim 11, and including the step of applying a predetermined resistance to the movement of the fabric through the flow path to reduce wrinkling of the fabric and maintain contact between the fabric and the rolls.

16. A method according to claim 11, wherein said surface elements are selected from the group consisting of grit, ribbon scrolls, spiral flutes, axially-extending edge members, chain and buttons.

17. A method according to claim 16, wherein each said outwardly-projecting edge member defines a wavy surface edge.

18. A method according to claim 16, wherein each said outwardly-projecting edge member defines a wavy surface edge wherein the wavy surface edge of each edge member is out-of-phase with the surface edge of any adjacent edge member.

19. A method according to claim 16, 17 or 18, wherein said edge members comprise are paired to define a v-shape in cross-section.