HEAT SETTING MACHINE WITH CONVEYOR
A continuous heat set line for setting yarn, having spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith. The entrance and exit cooling chambers and the intermediate heat-setting chamber collectively define a single longitudinally-extending axis along the combined length thereof. Sealing heads seal the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain a pressurized condition within the heat-setting chamber. A yarn conveyor extends through the pretreatment chamber for conveying the yarn through the entrance and exit cooling chambers and the heat-setting chamber in a position substantially equidistant or very nearly equidistant from top and bottom walls. At least one piston and cylinder assembly moves sealing rolls into and out of position relative to each other, while independently-operating springs urge the rolls together sufficiently to effect a seal.
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This application is a continuation of U.S. application Ser. No. 11/548,522 filed on Oct. 11, 2006, which was a divisional of U.S. application Ser. No. 10/392,497, filed on Mar. 20, 2003.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTIONThis invention relates to a machine and process for heat setting yarn, principally, but not exclusively, carpet yarn. The machine conditions twisted yarns with saturated steam to increase the crystallinity of the yarn and lock the twist or the crimp into the yarn. The machine is a continuous process machine with yarn entering one end of the machine, moving downstream through the machine and exiting the downstream end properly treated and ready for the next production step which is typically winding onto yarn packages in preparation for carpet tufting.
In general, the heat setting machine includes a coiler or other yarn-depositing device for depositing yarn on a moving conveyor which carries the yarn into a pretreatment chamber where the yarn is heated. The yarn then passes through a set of entrance sealing rolls which maintain a pressurized environment within the system. The yarn then passes into an entrance-cooling chamber where cool, dry air is circulated through the yarn, cooling the yarn to a uniform temperature and thus allowing redevelopment of the bulk in the yarn. This cooling chamber also protects the sealing rolls from the higher temperature of the heating chamber.
The yarn then passes into a heating chamber where a homogeneous mixture of steam and air is circulated through the yarn. The yarn exits the heating chamber into an exit-cooling chamber where cool dry air is circulated through the yarn to reduce the yarn temperature, remove excess moisture, and protect a set of exit sealing rolls which cooperate with the entrance sealing rolls to maintain a pressurized environment within the system. The yarn then passes through the exit sealing rolls and can be further dried, separated and wound onto packages on a take-up winder which runs in synchronization with the remaining components. A yarn accumulator can be part of the system, allowing the system to continue operating during winder doffing cycles.
Several features are provided which differentiate the machine and method disclosed in this application from prior art machines. These features include a tunnel wherein two cooling chambers on either end of a heating chamber communicate in alignment with each other along an axis extending the length of the combined cooling and heating chambers. There is no offset from one zone to the other. This permits less expensive manufacturing and a wider conveyor belt that can be positioned substantially equidistant from top and bottom walls of the chambers for transporting the yarn through the system.
The novel system also includes an entrance and exit set of sealing rollers which maintain the pressure in the system. These sets of rollers are moved into and out of sealing position by a novel power-assist assembly such as pneumatic or hydraulic cylinders. The rollers are locked into sealing with each other by a mechanical locking device that takes the load off of the power-assist assembly and places the load onto heavy springs which provide the resilience necessary to perform the sealing function while permitting the yarn to pass between the rollers into and out of the heating chamber.
SUMMARY OF THE INVENTIONTherefore, it is an object of the invention to provide a continuous heat set tunnel for setting yarn.
It is another object of the invention to provide a continuous heat set line that has a conveyor that extends generally along the lateral centerline of the heat set tunnel to thereby provide for an increased conveyor width.
It is another object of the invention to provide a continuous heat set line with sealing head rolls that are moved into and out of sealing position by at least one piston and cylinder assembly.
It is another object of the invention to provide a continuous heat set line with sealing head rolls that are pressurized against each other by springs operating independently of the piston and cylinder assembly.
These and other objects of the invention are achieved in the preferred embodiments disclosed below by providing a continuous heat set line for setting yarn. The line includes spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith. The entrance and exit cooling chambers and the intermediate heat-setting chamber collectively define a single longitudinally-extending axis along the combined length thereof. A steam injector is included for injecting steam at a predetermined pressure into the heat-setting chamber and a yarn conveyor extends through the entrance and exit cooling chambers and the heat-setting chamber at a position equidistant from a top and bottom wall thereof for conveying the yarn therethrough. The line also includes a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the entrance sealing means.
According to one preferred embodiment of the invention, the continuous heat set line further includes sealing means for sealing the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain a pressurized condition within the heat-setting chamber.
According to another preferred embodiment of the invention, the sealing means includes an entrance sealing roll apparatus positioned upstream of the entrance cooling chamber and an exit sealing roll apparatus positioned downstream of the exit cooling chamber for sealing, respectively, the upstream end of the entrance cooling chamber and the downstream end of the exit cooling chamber, each of the entrance and exit sealing roll apparatuses including a pair of sealing rolls positioned adjacent each other for allowing yarn on the conveying apparatus to pass therebetween while preventing the escape of pressurized steam from within the entrance and exit cooling chambers and the intermediate steam heat-setting chamber.
According to another preferred embodiment of the invention, the sealing means includes a frame defining an opening through which the conveyor extends and a bottom sealing roll assembly carried by the frame including a rotatably-mounted bottom sealing roll positioned below the conveyor. The sealing means may also include a top sealing roll assembly carried by the frame including a rotatably-mounted top sealing roll mounted in spaced-apart relation to the bottom sealing roll above the conveyor whereby the conveyor extends between the bottom sealing roll and the top sealing roll for carrying the yarn past the top and bottom sealing roll assemblies and into the entrance cooling chamber. At least one piston and cylinder assembly can interconnect the frame and the top sealing roll assembly for moving the top sealing roll assembly between an opened position, and a closed position wherein the top roll rests against the bottom roll. Also, the sealing means may include pressurizing means for exerting sufficient pressure on the top roll to seal the top roll against the conveyor and the yarn carried thereon as the conveyor is supported by the bottom roll.
According to another preferred embodiment of the invention, the pressurizing means of the sealing means includes springs carried by the frame for resiliently biasing the top roll against the yarn and conveyor when in its closed position.
According to another preferred embodiment of the invention, the sealing means includes lateral seals positioned to contact and seal against radially-extending end walls of the top roll and the bottom roll.
According to another preferred embodiment of the invention, the yarn depositing apparatus comprises a yarn coiler for depositing uniform, overlapping coils of yarn on the yarn conveying apparatus.
According to another preferred embodiment of the invention, the yarn conveyor includes an endless fluid permeable conveyor belt extending from the coiler to downstream of the exit cooling chamber.
According to another preferred embodiment of the invention, the continuous heat set line further includes a yarn packaging apparatus for removing the yarn from the yarn depositing apparatus and forming the yarn into a package suitable for further downstream processing.
According to another preferred embodiment of the invention, the continuous heat set line includes a locking lever for urging a top roll into contact with the conveyor.
According to another preferred embodiment of the invention, the line includes a locking pin for locking the locking lever into a position with the top roll urged into contact with the conveyor.
According to another preferred embodiment of the invention, the line includes a top lamella sealingly engaging a top roll along the length thereof to prevent the escape of steam and pressure past the top roll and a bottom lamella sealingly engaging a bottom roll along the length thereof to prevent the escape of steam and pressure past the bottom roll.
According to another preferred embodiment of the invention, a continuous heat set line for setting yarn includes spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith, the entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof. The line also includes a steam injector for injecting steam at a predetermined pressure into the heat-setting chamber and a steam pretreatment chamber positioned upstream of the entrance cooling chamber for applying a conditioning charge of steam to the yarn before it enters the entrance cooling chamber. Also, the line includes a yarn conveyor extending through the pretreatment chamber, the entrance and exit cooling chambers and the heat-setting chamber at a position equidistant from a top and a bottom wall thereof for conveying the yarn therethrough and a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the pretreatment chamber.
According to another preferred embodiment of the invention, a method of setting yarn includes the step of providing a continuous heat set line for setting yarn. The continuous heat set line includes spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith, the entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof. The line also includes a steam injector for injecting steam at a predetermined pressure into the heat-setting chamber and a steam pretreatment chamber positioned upstream of the entrance cooling chamber for applying a conditioning charge of steam to the yarn before it enters the entrance cooling chamber. The line further include a yarn conveyor extending through the entrance and exit cooling chambers and the heat-setting chamber at a position equidistant from top and bottom walls thereof and a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the pretreatment chamber. The method also includes conveying yarn through the continuous heat set line.
According to another preferred embodiment of the invention, the method also includes the step of sealing the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain a pressurized condition within the heat-setting chamber.
According to another preferred embodiment of the invention, the method also includes the step of circulating cool, dry air through yarn in the entrance cooling chamber.
BRIEF DESCRIPTION OF THE DRAWINGSSome 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:
Referring now specifically to the drawings, a cross-section of a portion of a tubular heat set tunnel according to a prior art design is illustrated in
The invention according to the present invention is disclosed in
The entrance cooling section 40 includes an exterior heat exchanger 42 which takes heated yarn from a pre-treatment steaming chamber, not shown, and circulates cool, dry air through the yarn by means of a fan 43, cooling the yarn to a uniform temperature and allowing bulk to redevelop in the yarn after passing under the rolls of the sealing roll assembly 20. See
The treated yarn passes through the heat/cool transition 54 into the exit cooling section which cools the yarn as it protects the rolls of the exit sealing roll assembly 30. The yarn is then conveyed to a winder where the yarn is packaged on suitable yarn packages and is ready for further processing.
The preferred embodiment of the heat set tunnel segment 51 is shown in
Another embodiment of a tunnel segment is shown in
Another embodiment of a tunnel segment is shown in
Another embodiment of a tunnel segment is shown in
The entrance roll sealing assembly 20 is shown in
The top sealing roll frame 126 carries a top sealing roll 130,
The sealing pressure against the rolls 123 and 130 necessary to prevent the escape of pressure is provided by opposed sets of heavy steel springs 135, 136 mounted between the top sealing roll frame 126 and a top pressure plate 138. Adjustment screws 139 and 140 permit adjustment of the springs to the correct pressure to seal the rolls 123 and 130 against each other while not creating so much pressure that the roll bearings are damaged.
The hydraulic cylinders 124A, 124B serve only to raise and lower the top sealing roll frame 126 relative to the bottom sealing roll frame 121. When, for example, the top sealing roll frame 126 has been lowered onto the bottom sealing roll frame 121 by the hydraulic cylinders 124A, 124B, pressure is applied to the rolls 123, 130 by means of a locking lever 150 which is manually urged into a locking link assembly 151. See
As is best shown in
Yarn passing through the entrance sealing roll assembly 20 on the conveyor belt 57 is compressed as it passes between the top and bottom sealing rolls 130, 123 to the extent that pressure cannot escape past the compressed yarn.
The entire entrance sealing roll assembly 20 can be covered by a protective shroud 170, as shown in FIGS. 13 and 9a.
As noted above, an identical exit roll sealing assembly 30 positioned in the exit end of the heat set tunnel 10 performs the identical function at the exit end, creating a closed environment for the heat set operation.
A heat setting machine with a sealing head 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. A continuous heat set line for setting yarn, comprising:
- (a) spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith, the entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof;
- (b) a steam injector for injecting steam at a predetermined pressure into the heat-setting chamber;
- (c) a yarn conveyor extending through the entrance and exit cooling chambers and the heat-setting chamber at a position equidistant from a top and bottom wall thereof for conveying the yarn therethrough; and
- (d) a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the entrance sealing means.
2. A continuous heat set line for setting yarn according to claim 1, further comprising sealing means for sealing the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain a pressurized condition within the heat-setting chamber.
3. A continuous heat set line according to claim 1, wherein the yarn depositing apparatus comprises a yarn coiler for depositing uniform, overlapping coils of yarn on the yarn conveying apparatus.
4. A continuous heat set line according to claim 1, wherein the yarn conveyor comprises an endless fluid permeable conveyor belt extending from the coiler to downstream of the exit cooling chamber.
5. A continuous heat set line according to claim 1, and including a yarn packaging apparatus for removing the yarn from the yarn depositing apparatus and forming the yarn into a package suitable for further downstream processing.
6. A continuous heat set line according to claim 1, wherein the sealing means comprises an entrance sealing roll apparatus positioned upstream of the entrance cooling chamber and an exit sealing roll apparatus positioned downstream of the exit cooling chamber for sealing, respectively, the upstream end of the entrance cooling chamber and the downstream end of the exit cooling chamber, each of the entrance and exit sealing roll apparatuses including a pair of sealing rolls positioned adjacent each other for allowing yarn on the conveying apparatus to pass therebetween while preventing the escape of pressurized steam from within the entrance and exit cooling chambers and the intermediate steam heat-setting chamber.
7. A continuous heat set line according to claim 2, wherein the sealing means comprises:
- (a) a frame defining an opening through which the conveyor extends;
- (b) a bottom sealing roll assembly carried by the frame, including a rotatably-mounted bottom sealing roll positioned below the conveyor;
- (c) a top sealing roll assembly carried by the frame, and including a rotatably-mounted top sealing roll mounted in spaced-apart relation to the bottom sealing roll above the conveyor whereby the conveyor extends between the bottom sealing roll and the top sealing roll for carrying the yarn past the top and bottom sealing roll assemblies and into the entrance cooling chamber;
- (d) at least one piston and cylinder assembly interconnecting the frame and the top sealing roll assembly for moving the top sealing roll assembly between an opened position, and a closed position wherein the top roll rests against the bottom roll; and
- (e) pressurizing means for exerting sufficient pressure on the top roll to seal the top roll against the conveyor and the yarn carried thereon as the conveyor is supported by the bottom roll.
8. A continuous heat set line according to claim 7, wherein the pressurizing means comprises springs carried by the frame for resiliently biasing the top roll against the yarn and conveyor when in its closed position.
9. A continuous heat set line according to claim 8, wherein the sealing means includes lateral seals positioned to contact and seal against radially-extending end walls of the top roll and the bottom roll.
10. A continuous heat set line according to claim 1, further including a locking lever for urging a top roll into contact with the conveyor.
11. A continuous heat set line according to claim 10, further including a locking pin for locking the locking lever into a position with the top roll urged into contact with the conveyor.
12. A continuous heat set line according to claim 1, and including a top lamella sealingly engaging a top roll along the length thereof to prevent the escape of steam and pressure past the top roll and a bottom lamella sealingly engaging a bottom roll along the length thereof to prevent the escape of steam and pressure past the bottom roll.
13. A continuous heat set line for setting yarn, comprising:
- (a) spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith, the entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof;
- (b) a steam injector for injecting steam at a predetermined pressure into the heat-setting chamber;
- (c) a steam pretreatment chamber positioned upstream of the entrance cooling chamber for applying a conditioning charge of steam to the yarn before it enters the entrance cooling chamber;
- (d) a yarn conveyor extending through the pretreatment chamber, the entrance and exit cooling chambers and the heat-setting chamber at a position equidistant from a top and a bottom wall thereof for conveying the yarn therethrough; and
- (e) a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the pretreatment chamber.
14. A method of setting yarn comprising the steps of:
- (a) providing a continuous heat set line for setting yarn, comprising: (i) spaced-apart, elongate, tubular entrance and exit cooling chambers interconnected by an elongate intermediate steam heat-setting chamber communicating therewith, the entrance and exit cooling chambers and the intermediate heat-setting chamber collectively defining a single longitudinally-extending axis along the combined length thereof; (ii) a steam injector for injecting steam at a predetermined pressure into the heat-setting chamber; (iii) a steam pretreatment chamber positioned upstream of the entrance cooling chamber for applying a conditioning charge of steam to the yarn before it enters the entrance cooling chamber; (iv) a yarn conveyor extending through the entrance and exit cooling chambers and the heat-setting chamber at a position substantially equidistant from top and bottom walls thereof; and (v) a yarn depositing apparatus for depositing yarn in a uniform manner on the yarn conveyor upstream of the pretreatment chamber;
- (b) conveying yarn through the continuous heat set line.
15. The method according to claim 14, further comprising the step of sealing the entrance and exit cooling chambers and the intermediate heat-setting chamber to a degree sufficient to maintain a pressurized condition within the heat-setting chamber.
16. The method according to claim 15, further comprising the step of circulating cool, dry air through yarn in the entrance cooling chamber.
Type: Application
Filed: Jun 20, 2007
Publication Date: Oct 11, 2007
Applicant: BMB Enterprises, Inc. (Dalton, GA)
Inventors: Jeffrey Rhyne (Belmont, NC), Edward Smith (Dalton, GA), Robert Miller (Dalton, GA), Joseph Gottberg (Mooresville, NC)
Application Number: 11/765,777
International Classification: D02J 13/00 (20060101);