Note: Descriptions are shown in the official language in which they were submitted.
109 709~ .
DISCL~SURE
The present invention is concerned with a pro-
cess for the application of liquid treating agents to
textile fabrics.
BACKGROUND O~ THE INVEN~ION
A commonly used procedure for applying liquid
treating agents to fabrics is padding, which involves
immersion of the fa~ric in the liquid and then
s~ueezing the fabric to impregnate the fabric and expel
excess liquid. In spite of the squeezin~ action of the
pad rolls, large quantities of liquid are taken up in
the fabric. Subsequently, the fabric must be dried and
therefore lar~e amounts of heat must be applied to -
cause al~ o~ this water to evaporate. As a result, the
ener~y requirements o~ textile finishing operat~ons are
very substantial. Another procedure invol~es spraying
the liquid onto the surface of the fabric. Spraying
permits better control of the amount of liquid applied.
However, it also reduces the penetration o~ the liquid
into the fabric which, in many, if not most, ca~es
limits the usefulness o~ the process. Attempts ha~e
been made t~ use suction to draw the liquid into the
abric, but the penetration achieved ~as much less than
observed in padding~
.~
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~09~7~94
SUMMARY OF THE INVENTION
The present invention is concerned with a pro-
cess for applying liquid to fabrics which is capable
- of applying small quantities to the surface of the
fabrics and then working those small amounts of liquid
into the fabric. As a result, the deep penetration,
characteristic of a padding process is achieved at much
lower liquid application rates. Therefore, the energy
re~uired to remove water is reduced, and even eliminated
entirely in some cases.
In accordance with the present invention, the
fabric is squeeæed between a pair of large diameter
soft rubber rolls which are rotated so that their
surfaces move in the same direction as the fabric. A
thin film of liquid is applied to the surface of one or
both of the rubber rolls which is transferred to the
surface of the fabric as the fabric is propelled
between the rolls. The action of the rolls then moves
the liquid into the interior of the fabric. By con-
trolling the pressure o the rolls and the amount ofliquid applied, it is possible to control the penetra-
tion of liquid into the fabric to achieve a variety of
interesting effects.
:
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lV~7094
BRIEF DESCRIPTION OF DRAWING
-
The process will be understood more readily
from the detailed description of preferred embodiments
which follows, reference being made to the drawing in
which:
FIGURE 1 is a schematic illustration of a
transfer padding apparatus useful in carrying out the
process of the invention;
FIGURE 2 is a schematic illustration of the
apparatus of FIGURE 1, depicting an alternate mode of
operation which is used when especially small quanti-
ties of liquid are to be applied;
FIGURE 3 is a schematic view on enlarged scale
of a portion of FIGURE 1, showing the action of the
pad rolls on the fabric.
:~o~
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DETAILED DESCRIPTION OF PREFERRED EMBODIME~TS
As illustrated in FIGURE 1, the process consists
of passing a fabric 1 between a pair of pad rolls 2 and
3 which are rotated so that their surfaces move in the
same direction as the fabric. The pad rolls typically
comprise a soft rubber cover 4 enclosing a metal shaft
5. The rolls are pressed against the fabric with
sufficient pressure to flatten their surfaces along a
contact zone 6 between the rolls, extending along the
direction in which the fabric is moving. A bowed roll
7 is provided just below the nip between the pad rolls
which feathers the fabric in the contact zone 6. Below
the pad rolls 2 and 3 there are transfer rolls 8 and 9
which apply liquid to the surfaces of the pad rolls.
In the embodiment shown in FIGURE 1, the transfer
rolls 8 and 9 are rotated in the same direction as the
pad rolls 2 and 3; thus the surfaces of the transfer
rolls and the pad rolls move in opposite directions
where these rolls come together. The transfer rolls 8
and 9 may be covered with hard rubber, but preferably
they may ha~e metal sur~aces.
Below the transfer rolls 8 and 9 therP are
meter rolls 10 and 11 which are partially immersed in
li~uid treating agents in pans 12 and 13. The meter
rolls travel in the opposite direction from transfer
rolls ~ and 9 so that the surface of the transer and
meter rolls travel in the same direction where they
come together. The meter rolls may be of the same
construction as the transfer rolls.
In operation, all of the rolls are rotated
by motors or other power means (not shown in the
drawing) through sprocket chains as shown. However,
only one of the pad rolls is driven b~ a motor; the
other pad roll is mounted so that it can rotate ~reely,
1~7~f~
--6--
but it is driven by the first pad roll through the
fabric. Each meter roll lifts liquid as it emerges
from the pan in which it is partially immersed, in the
form of a film of liquid on the surface of the meter
roll. At the junctures of ~he meter rolls and the
transfer rolls, a clearance is provided which allows a
thin film of liquid to be transferred from the meter
rolls to the transfer rolls. Usually, the clearance
will be 0.004 to 0~011 inch. Howeverl larger clear-
ances may be used, for example 0.020 to 0.030 forheavier application rates, e.g., latex applied to a
carpet back. At the juncture of the transfer rolls and
the pad rolls, a similar transfer occurs to form thin
films of liquid on the pad rolls. At that location,
the transfer roll preferably is in contact with the
pad roll or pressed into the pad roll 0.004 or 0.005
inch more or less. However, if very light application
rate is desired, it may be desirable to space the trans-
fer roll from the pad roll; this is rarely if ever
necessary.
By adjusting the clearance between the rolls
and the relative speeds of the rolls~ the thickness of
the films of liquid on the pad rolls can be adjusted.
Preferably, the pad roll runs 0.5 to 4 times the
surface spePd of the transfer roli and the meter roll
runs 0.5 to 4 times the surface speed of the tran~fer
roll. For heavier~fabrics, in general, the meter and
the transfex rolls are turned more slowly so that more
liquid is applied to the pad rolls and transferred to
the fabric. The speedæ of the pad roll may be
increased still further, relative to the transfer roll
and a surface speed ratio of 7.5 to 1 may be used in
some cases. Higher pad roll speeds reduce the thick-
ness of the film of liquid on the pad roll and thus
the amount of liquid applied. However, caution must
10~
-7
be taken because in some cases, surface tension may
break the fllm, depending on the rheology of the particu-
lar liquid. The surface speed of the metering roll
preferably should be at least 75 feet per minute. On
the other hand, excessive metering roll speed should
be avoided since it will cause slinging of the liquid.
The maximum speed depends on the rheology of the liquid
and the diameter of the metering roll, as smaller
rolls and less ~iscous liquids are more vulnerable to
slinging.
It has been found desirable that the metering
roll be rotated at sufficient speed to maintain a
flooded nip, i.e., the space between the metering roll
and the transfer roll must be filled at all times. The
necessary rotational speed is easily recognized by the
back flow pattern on the metering roll during opera-
tion. For a given fabric, the pad roll to transfer
roll surface speed ratio and the metering roll to
transfer roll surface speed ratio can be adjusted to
achieve the desired application rate while maintaining
the requisite metering roll speed. As an illustration,
in a machine with 18" diameter pad rolls and 12" steel
transfer and meter rolls the following conditions
achie~e similar metering roll rotational speeds at
operating speeds of 100 yards per minute and 60 yards
per minute:
Fabric weight: 9.50 oz./s~.yd. Wet pickup: 12.5%
Roll space - Metering to Transfer Roll 7 mils
at 100 ypm at 60 ypm
Ratio of pad roll speed to
transfer roll speed (surface
speed ratio) 1.60 1.30
Ratio of meter roll speed to
transfer roll speed (surface
speed ratio) 1.75 2.35
Meter Roli Rotational Speed
(RPM) 104 104
~L0~7~4
--8
C~ntrol of both the ratio of surface speeds
which, in conjunction with the roll spacing, determines
the amount of mix applied to the fabric and control of
rotational speed to accommodate to machine operating
conditions, mix viscosity and wetting characteristics
allows extreme latitude in establishing and optimizing
applicati~n conditions for a given fabric.
FI~URE 2 schematically illustrates an alterna-
tive embodiment adapted to apply smaller amounts of
li~uid to the fabric. This embodiment differs from the
embodiment in FIGURE 1 in that the directions of rota-
tion of rolls 8, 9, 10 and 11 all are reversed. In
general, the amount of liquid applied to the pad rolls
is less in this embodiment.
An important feature of the present invention
is the use of soft pad rolls of relatively large diam-
eter. In general, it has been ~ound desirable to use
rolls having an exterior layer of elastomeric material
which is resistant to the treating liquid. The rubber
may be, for example, neoprene or natural rubber,
depending upon th~ composition of the liquid. ~he
elastomeric material preferably is es~entially solid,
as distinguished from porous, cellular or foamea
- elastomers. Furthermore, the surface of the elastomer
is preferably smooth and level. Thus, the process does
not function by absorbing li~uid in a porous roll
covering but by carrying a thin layer of liquid on the
surface of the pad roll.
It will be reali2ed that small surface or
interior imperfections which sometimes occur in rubber
products may be present. In addition, while a foamed
or cellular elastomer is neither necessary nor desir-
able, a smooth or continuous-surfaced foamed elastomer
may be u~ed, provided it possesses the necessary
stiffness.
~097~
g
The soft pad rolls usually will have an
exterior diameter of 12 to 24 inches although smaller
and larger rolls may be used. The hardness of the
rubber layer should be less than about 75 durometer and
preferably more than 30 durometer Shore A. Rubber
which is too hard requires too much pressure to func-
tion and, therefore, will crush the fabric. Rubber
which is too soft may not be durable.
Another important featuxe of the invention
resides in the pressure applied between the pad rolls.
The applied force is chosen depending upon the hardness
of the rubber covering on the rolls and the thickness
of that covering. The force should be sufficient to
provide a contact zone extending at least 1/2 inch
along the fabric. In actual practice, the contact zone
has been 3/4 to 1 inch long and, although not essential,
that length is much preferred. The applied pressure
and the length of the contact zone depend, to some
extent, on the effect desired in the process, the
construction of the fabric and the weight of the
fabric; these factors can be determined by simple
experimentation. Generally these rolls are pressed
against opposite sides of the fabric with a force of at
least about 10 psi, although a contact pressure of at
least 25 psi is preferred. Usin~ a 45 durometer (Shore
A) rubber roll, it has been ~ound that the length of
the contact zone and the effectiveness of the process
does not vary much using contact pressures of 20-350
psi, so long as there is sufficient pressure for the
driven pad r~11 to drive the other pad roli. With a
pressure of 50 psi, the contact zone was 3/4 inch and
at 350 psi it was about 1 inch. The contact pressure
depends on the hardness of the rubber. It is found in
practice that the presssure is greatest at the ends o~
the rolls and less along the central portions.
.
109~09~
~10-
The pad rolls normally comprise a rubber
covering on a steel roll, since this provides a more
durable roll. The covering may be as thin as l/8 incn.
As the fabric moves between the pad rolls, the
rubber is flexed as it is flattened in the contact æone
causing a manipulation of the fabric. While not fully
understood, it is believed that some flexing or
stretching takes place in the fabric which moves fibers
relative to each other. A standing wave is believed to
form along the surfaces of the rolls and possibly along
the fabric. The action forces liquid through the
fabric, from the surface to which it is applied, toward
or to the opposite surface. The depth of penetration
depends, to some degree, on the roll pressure, the
amount of liquid applied, the length of the contact
zone 6 and the weight and construction of the fabric.
However, the liquid penetration is distinctly different
from the surface application observed with hard rubber
rolls.
An important advantage of the present invention
is the abili~y to apply very small amounts of liquid
to a fabric and yet insure full penetration. In
appropriate circum~tances, it is possible to apply
sufficiently little liquid, for example, dye liquor,
that the fabric need not be dried before it is wound,
resulting in substantial savings in energy. In other
cases, where some drying is necessary, the amount of
energy required i8 much less. For example, drying and
curing time for application of durable press resins to
bedshee* ~abric can be reduced from 90 seconds to 13
seconds.
Another advantage of the process is that it
makes it possible to avoid migration of treating agents
to the surfaces of the textile. In contrast, when
textiles are saturated with water soluble dyestuffs or
7~
durable press resins, there is a tendency for the
agents to migrate to the surfaces of the textilP during
drying. In accordance with the present invention, it
is possible to apply just enough water with the treating
agent to distribute water within the fib~rs as inter-
stitial water, without filling the capillaries between
fibers. Typically, this will involve wet pick-ups of
say 10-20% of the dry fabric weight. At such low appli-
cation rates, water and the water soluble treating
agents are distributed substantially uniformly through
the fabric, but they do not migrate to the surface. By
contrast, with conventional padding, it normally is
difficult to obtain wet pick-ups less than 60%.
The present invention is applicable to a wide
~ariety of textiles including natural, man-made and
synthetic fibers. Natural fibers to which the invention
may be applied include regenerated cellulose (rayon),
cellulose acetate and cellulose triacetate. Synthetic
fibers which may be used include polyamide (nylon 6 and
66), polyester (polyethylene terephthalate), polyolefin
(polyethylene and polypropylene), acrylic (polyacrylo-
- nitrile) and modacrylic, as well as various blends.
The fabrics may be nonwoven fabrics, flocked fabrics or
woven or knitted fabrics made with continuous filament
and~or spun yarns. The invention may be used with
~abrics having a weight of, e.g., 1 to more than 24
ounces per square yard. The.invention also is applic-
able to warp sizing.
A wide variety of treating agents may be
applied, including all finishing agents commonly
applied to textiles, both water soluble and water-dis-
persed, such as bleach, dyes, sizes, various resins and
water repellents.
Interesting effects can be achieved because of
the controlled penetration produced by the present
l~9t7~9,~
invention. For example, it is possible to apply two
different treating agents with the respecti~e pad rolls,
even though those treating agents are not compatible in
a single bath. Thus, in applying a durable press
resin, one impregnates with a solution containing both
resin and catalyst. However, in some cases, the
ca~alyst can cause premature polymerization of the
resin. By separately applying the resin and catalyst
solutions, in accordance with the present invention,
the resin and catalyst do not contact each other until
- they have been applied to a fabric. Furthermore,
through the application of diminished amounts of resin,
it is possible to stabilize the fabxic dimensionally
and achieve some crease resistance without making the
fabric stiff or boardy. Alternatively, the resin and
catalyst can be applied together from one side of the
fabric at a very low application rate. If the applica-
tion rate is su-fficiently low, having regard to the
weight of the fabric, the resin can penetrate suffici-
ently to stabilize the fabric dimensionally withoutaffecting-fibers on the opposite surface. While this
~ procedure surrenders the advantage of separately
applying catalyst and resin, the natural hand of, say,
a cotton fabric can be preser~ed e~en though the fabric
possesses the dimensional stability and crease resist-
ance of a duxable press fabric.
In another embodiment, in which, for example, a
d~nim fabric is treated with resin, only a ~ery light
application of resin is made from one side of the
fabric. For instance, the resin application may be a
5% wet pick-up of a 40~ solution o resin. As a result
of the limited penetrat~on of resin, the resin fixes
the fabric near one suxface and stabilizes the dim~n-
sions of the fabric. Howe~er~ the resin does not
penetrate deep in~o the interior o~ the fabric. This
~C~97l)~
-13-
is important in the case o denim fabrics which the
public desires to fade during laundering. In other
words, the resin does not prevent desired washdown of
dyes, but it does pro~ide dimensional stability in the
form of resistance to shrinkage.
Other interesting eff~ts can be achieved by
applying dyestuffs with the process of the present
invention. For example, two different dyestuffs can be
applied from opposite sides of fabrics at controlled
rates and in sufficient quantities to penetrate through
the fabric. Unlike continuous dye processes involving
exhaustion of dyes into a fabric, it is possible to
provide continuous control of the color of the fabric
and assure that each successive len~th of fabric has
the same color.
Another advantage of the present invention is
observed in the treatment of knit fabrics which are
constructed of ayed yarns. Whereas some treatments of
yarn dyed fabrics may cause pattern distortion, the
soft pad rolls used in the present invention minimize
or avoid this difficulty.
The following examples illustrate the invention.
Unless otherwise indicated, proportions are on a
- weight basis. The designation "M to T roll space"
refers to the space between the meter and transfer
rolls. The designation UP/T" is the ratio of the
sur~ace speed of the pad roll to the surface speed of
the transfer roll. ~he designation "M/T" is the ratio
~ the surface speed o~ the meter roll to the surface
3a speed o~ the trans~er roll. The references to "~ace"
and "back" relate to the face and back of the fabric~
the compositions applied respectively to the ~ace and
back of the fabric, and the rolls which make the
respective applications. In these examples, steel
meter and transfer rolls were used. The pad rolls were
:1(35~
-14-
in contact with the transfer rolls. The transfer and
meter rolls were lO inches diameter, 72-inch face. The
pad roll was 18 inches diameter, including a l-inch
thick layer of 45 durometer rubber (Shore A) over a
steel shaft. Pressures between the pad rolls were
above 20 psi and sufficient for the driven pad roll to
drive the other pad roll through the fabric. Unlesc
otherwise indicated, the fabric speed was 30 yards per
minute.
The test procedures utilized were as follows:
Grab Break.......... ANSI/ASTM Dl682-64
(Reapproved 1975)
See "Grab Tests, G")
Elmendoxf Tear...... ANSI/ASTM D1424-63
~Reapproved 1975)
Appearance Rating.. AATCC-124
Flex Abrasion...~.. ANSI/ASTM Dl175-71
Flexing and Abrasion Method
~0~7() ~4
-15-
EXAMPLE 1
Sample 1
Fabric: Indigo dyed denim, desized, 12.25 oz./sq.yd.
prepared for finishing.
Machine Settings:
. Face Rolls Back Rolls
M to T roll space 5 mils 5 mils
P/T 1.20 1.50
M/T 1.20 . 1.95
% Wet pickup 12.5 7
Mixes Applied:
Fabric Face:
Emulsified fatty alcohol
softener 3.75
Fabric Back:
Acrylic resin emulsion 20%
Glyoxal-urea-formaldehyde
condensate 10%
High density polyethylene
emulsion 1.7%
Magnesium salt catalyst 6~7%
Long chain alcohol ethylene
oxide condensate wetting
agent ` 0.38%
25 Drying and ten~ring. 18 seconds at 275F.
Mechanical compressi~e shrinkage a~ter
drying and tentering: 4-1/2 inches/yard
'~
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--16--
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o ~ ~-- ~u ~ n ~D~ ~D ~ H
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1097094
-17-
In these samples the differences in breaking
strength as compared to regular production appear to be
accounted for in the increased flexibility of the fabric
as evidenced in increased tear strength and abrasion
resistance. The overall performance of Samples 1 and
2 was considered excellent.
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-18-
EXAMPLE 2
Sample 1
Fabric: Corduroy, 50% polyester/50% cotton warp,
100% cotton filling 9.25 oz./sq.yd.
Machine Settings:
Face Rolls Back Rolls
- M to T roll space 5 mils- 5 mils
P/T 1.20 1.20
M~T 1.30 2.40
% Wet pickup 15 10
Mixes Applied:
abric Face:
Emulsified fatty alochol
softener 3.3%
Polyol defoamer 0.05%
Fabric Back:
Acrylic resin emulsion 15.6
Glyoxal-urea-formaldehyde
condensate 15.6%
High density polyethylene
emulsion 7.24
Magnesium salt catalyst 7.2%
Long chain alcohol ethylene
oxide condensate wetting
agent 0.375%
Polyol defoamer 0.05%
Drying 18 seconds at 300F.
Curing ~0 seconds at 325F.
,
:~0~'7~
--19--
* ~ U~ ~ U)
~ ~ s ,t
~1 t3 o ~n ~ ~ X 3 X ~ ra ~
r~ 14 ~: m ~ ~ ~_
O O ~ ~ C~~ ~S tD
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~ t tD i
n ~ ~ lD n
~ ~ t~ U~ b~
t O
tn n
r~ ~n o) ~ ~4 1-- fD
r o
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S o
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O ~ 1 ~ :5
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~' ~X X
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o ~ ~ PJ
co ~ ~ I n
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t
a~
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XX X Y ID
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r~
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d~
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a~ y l~ ~ sa
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109'-~V~
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Improved filling shrinkage control and improvad
appearance with a maintenance of filling breaking
strength were particularly important for these fabrics.
With corduroy fabrics it was found that :~-
softness of hand could be adjusted readily by control ofthe amount and type of softener applied to the face and
choice of acrylic resin emulsion applied to the back.
In a further comparison it was found that
corduroy treated in accordance with the invention could
be dried and cured in 30 seconds at 380F by simply
passing through a tenter frame. In order to dry only a
saturation padded fabric at the same speed it was
necessary to employ a high capacity predryer.
Other corduroy fabrics, including 100% cotton
corduroy and corduroy containing 50% polyester, 50%
cotton yarns in both warp and filling, have been
processed satisfactorily by the same method.
' : :
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~(~9
-21-
EXAMPLE 3
Fabric: 11 oz/sq.yd. cotton denim.
Machine Settings:
Sample
7-1 7-2 7-3
Face Rolls
M/T space mils 5 5 5
P/T 2~00 1.60 1.20
M/T 2.25 1.70 1.70
Back Rolls
M to T space, mils 6 6 6
P/T 1.60 1.20 1.00
M/T 2.20 1.35 1.15
Wet pickup anticipated
Face 5% 7.5% 10%
Back 10% 15% 20~
Mixes Ap~lied: -
Face Emulsified fatty alcohol softener 2.5%
Back Emulsified acrylic polymer resin 10%
Glyoxal-urea-formaldehyde condensate 15%
High density polyethylene emulsion,1.7%
Zinc nitrate catalyst solution 2.8%
Linear alcohol ethylene oxide
condensate wetting agent 0.38%
The mixes were applied and the ~abrics were
dried on a tenter frame in 18 seconds at 275F. -
The fabrics were compressi~ely shrunk as a
final finishing step.
.
: . ' , , .' - . ,, . .: ::' ' .':
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--22
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.
~7()5~4
Another set of ~amples were prepared from this
fabric in which the mix components were varied to
achieve maximum softness o~ the finished fabric and to
determine effects on fabric p~ysical properties.
5 Machine Settings: 7-4 and 7-5
Face ~ to T roll space 5 mils
P/T 1.30
M/T 1.50
Back M to T roll space 6 mils
P~T 1.15
M/T 1.25
Wet Pickup, Face 10%
Back 15%
Mixes:
15 Face Mix Emulsified ~atty alcohol softener 5%
Bac~ Mixes 7-4 7-5
Fmulsified acrylic resin 6.7% 3.4~
Glyoxal-urea-~ormaldehyde 13.4% 13.4%
High density polyethylene
emulsion 1.7% 1.7%
Zinc nitrate catalyst6.7% ~ 6.7%
Wetting agent 0.38~ 0.38%
The ~abric was dried 12 seconds at 275F and
then compressively shrunk.
25 Fabric Properties 7-4 7-5
Grab Break, lb, W X F 166 X 78 168 X 88
Elmendorf Tear, lb, W X F25.5 X 12.8 23.5 X 14.1
Appearance Rating 4.0 3.9
Shrinkage
. 30 5 Home Launders0.3+ X 0.1 1~2 X O.3
: Flex Abrasion cycles 3940 X 1900 3860 X 2850
:~.()9~ 4
-~4-
Although the hand was extremely sot, excessive
catalyst caused some deterioration in fabric strength.
Note that all curing occurs within the period o time
that the abric is heated on the drying cylinder of the
compressive shrinkage machine.
Total time for drying and curing of the fabric
may be 18 seconds or less depending upon abric weight,
steam pressure and cylinder dimensions, although the
time may ~e increased if desired.
, .
~S''7~4
-25-
ExAMæLE 4
Fabric: Light weight denim fabric 9.O oz./sq.yd.
Indigo dyed.
Machine Settings Face Back
M to T roll space 5 mils 11 mils
P/T 1.65 1.55
M/T 2.35 2.40
Wet pickup 7.5~ 17.5%
Face Mix: Emulsified fatty alcohol softener - 4%
Long chain alcohol ethylene oxide wetting
agent - 0.25%
Back Mix: Emulsified fatty alcohol softener - 2%
Acrylic resin emulsion - 8%
Glyco}-urea-formaldehyde resin - 8%
Long chain alcohol ethylene oxide
- wetting agent - 0.25%
Zinc nitrate catalyst - 1.7%
Operational speed: 100-110 yards per minute.
Drying time: 16-18 seconds ~predryer eliminated~.
Compressive shrinkage: 4.5 inche~ per yard.
The finished denim fabrics were characterized
by a soft, supple hand, good strength retention, good
laundered appearances and excellent shrinkage control.
Of primary importance was the fact that the finished
denim fabri~s did not exhibit any growth, which causes
increased shrinkage, in storage. This is a common
characteristic o~ regular production of soft denims.
The operating speed was ~aster ~han ~ormal
for this ~abric when saturation padded, the normal
cpeed being 55 to 60 yards per minute and drying time
was 30-33 seconds plus approximately 20 seconds in a
predryer.
10~094
-26-
EXA~PLE 5
Fabric: Type 180 50~ cotton/50% polyester
sheeting 3.85 oz./yd2.
Sample
5 Machine Settings: 6 6-B 6-C
M to T space 5 mils5 mils 5 mils
P/T . 3.002.50 1.65
M/T 3.303.20 3.00
Wet pickup, % 15 20 30
Ratios were the same for face and back rolls
wet pickup was the same for face and back.
The finishing mi~ Ifrcoe aA~ back) contained:
Alkyl carbamate formaldehyde condensate 18%
Magnesium phosphate catalyst 6.4
Linear alcohol ethylene oxide condensate 0.5
Emulsified fatty alcohol softener 2.0
Drying time 12 seconds at 350F.
~ hree replications were made using a different
machine setting to obtain the same wet pickups with the
same alkyl carbamate fi~ish, as follows:
6-D 6-E 6-F
~ to T space 5 mils 5 mils 5 mils
: P/T 2.85 2.35 1.85
M/T 3.70 3.35 2.65
25 Wet pickup, % 15 20 30
.
' -' ` ' ` . .
-27-
On analysis of the fabrics for formaldehyde
content the averages found were:
Ratio Ratio of
of Wet Formaldehyde
Pickup Fabric Content to
Indicated to 15~ Formaldehyde Content at
Wet Pickup Pickup Content, % 15% Wet Pickup
15% 1.0 0.32 1.0
20% 1.33 0.42 1.31
10 30% 2.0 0.65 2.0
Fabric Performance Properties:
Indicated Appearance Rating Shrinkage, W X F, %
Wet Pickup A~C-124 -- 5 Home Launders
~ .
15% 3.1 2.0 X 0.7
15 20% 3.4 1.7 X 0.6
30% 3.8 1.4 X 0.6
ExAMæLE 6
Fa~ric: Striped tubular cotton jersey knit
weighing 4.05 oz./sq.yd.
20 Machine Settings:
M to T roll space both sides 4 mils
P/Tl, P/T2 2.75
Ml/Tl r M2/T2
Wet pickup, % 5
Mix appl ed on both s_des:
25 High density polyethylene emulsion 5%
Diethylene glycol 5%
: Phosphated alkyl phenol ethylene oxide
condensate wetting agent 0.44
Drying: None required since the amount of
moisture applied was less than normal regain for
the fabric.
-2~-
Processing: The fabric processed smoothly
without distortion. The stripes remained true and
there was no slippage between surfaces of the fabric.
Moisture content found: Side l 4.5%
Side 2 4.7
Average 4.6%~
Estimated total add on 5.1%
EXAMPLE 7
Application of a dip solution to one side of a
fabric. A bleached percale sheeting of 50% polyester
and 50% cotton was processed to determine uniformity at
application at several settings.
Parameters: Fabric weight - 3.70 oz./yd.2,
Overbite, transfer roll to pad roll - 8 to 11 mils
15 Mix Applied: % by weight
B ! Triton X-35 twetting agent) 0.25
Griffwet NB-106 (wetting agent) 0.25
Nylomine Green C~3G (Dye) 0.20
Diethylene glycol (lubricant) 1.0
M to T
Sample P/T M/T Roll Space % Wet Pickup
l 2.00 3.05 4 mils 10
2 1.40 1.90 4 20
3 1.20 1.30 4 30
The niP Pressure between the Pad rolls was
aP~roximatelY 55 lbs./linear inch. The fabric was
Processed at 60 FPm. It was dried 18 seconds at 350F
on a tenter frame.
le ~r?ark~
~' ~
1097U~4
-2~-
Sample uniformity was evaluated visually as
follows:
Sample #l - Some barre' ef~ects due to
variation in fabric construction
were visible while the fabric was
wet but were not apparent in the
dry ~abric.
Sample #2 ~ Uniform application.
Sample ~3 - Uniform application side to side,
end to end and face to back.
The depth of color increased uniformly from
Sample 1 through Sample 3. This example illustrates
that color can be applied uniformly through a fabric at
}ow moisture add on and that the usual procedure of
saturation followed by squeezing out o~ excess solution
is not necessary for color uniformity. An important
point is that the total water content o these fabrics
i~ far less in every case than conventional saturatio~
padding in which solution pickup is generally 60%
greater a~ter excess solu~ion is squeezed from the
fabric.
EXAMPLE 8
In a similar series of samples in which a blue
dye solution was applied to one side o sheeting
fabric and a yellow dye solution to the other side of
the fabric and wet pickup on each side was varied from
about 5% to 30% on the weight o~ the fabric, it was
~ound that a green colored ~abric was usually produced.
The shade and depth o~ color varied depending upon the
relative amounts of blue and yellow dye solutions
~ applied and the total amount applied. At the lowest
wet pickup on each side~ however, the fabric was
bicolored, that is one side was yellow by reflected
light. By transmitted light the ~abric was green.
-30-
Application of dyes at low wet pickups to oth~r
fabrics gave some very novel efects. On a terry fabric
similar to terry toweling, it was possible to dye the terry
loops different colors on each side of the fabric. The
depth of penetration o~ the color into the towel loops
was controlled by adjusting the wet pickup of dye solu-
tion of each side of the fabric. The colors were applied
simultaneously to both sides of the fabric.
Bicolored fabrics have been produced by simul-
taneous application of different colors to each side ofthe ~abrics as described by restricting wet pickup on
each side even where the dye solutions are compatible.
Another method of obtaining bicolored fabric is to use
mutually incompatible solutions. For example a dye
solution containing 2% by weight of disodium hydrogen
phosphate was applied to one side of a fabric, a second
dye solution containing .2% by weight of zinc chloride
was applied to the other side of the fabric. Precipi-
tation at the interface effectively prevented mixing of
the dyes and provided a bicolored fabric. Wet pickup
on each side was 15% based on the weight of the fabric.
Many other pairs of incompatible reagents which precipi-
tate or form a barrier on contact may be used. The
relative amounts of each solution applied may be varied
to control the effective dividing line between solutions
in the fabric. The use of mutually reacti~e or incom-
patible solutions is not restricted to color.
Many other fabrics have been proce~sed by
application of ~he same or different formulations to
face and back of fabric. The amount applied to face
and back has been and can be varied at will over a
wide range. Minimal amounts of material can be
applied.
~0~
-31-
The fabrics processed have included light
weight sheeting and heavy denim, and corduroys of all
cotton and polyester/cotton fiber blends, brushed
fabrics have been processed to achieve a soft smooth
fabric face and, simultaneously, excellent wash
performance. Because the fabric has such short contact
with the transfer padding machine, mechanical distortion
in processing is reduced appreciably. This allows
processing of delicate or unstable fabrics such as
knits, corduroys, brushed fabrics and soft fabrics
without distortion.
Because the invention provides control of
moisture content, significant increases in output are
possible. An increase in operating speed from the
range of 55-60 ypm up to 110 ypm on a denim fabric
while simultaneously eliminating the necessi~y for a
predrying step was achieved. Fabrics have been
processed satisfactorily at speeds such that the drying
time has been reduced to 10 seconds or less. It is
apparent that proper utilization of the transfer
padding machine can eliminate a significant part of the
fabric drying load and provide unique finished fabrics.
Warp sizing has been applied to fabric as part
of a study to determine the adaptability of the machine
to y~rn slashing. Uniformity and distribution of the
size within sized fabrics appeared to be much improved
as compared to slashed yarn. Again drying loads in
yarn slashing can be reduced appreciably.
A very novel aspect of the machine is the
ability to control wet pickup through variation in
suxface speeds of the metering and transfer rolls.
Precise control of these roll speeds has bsen obtained
by both mechanical drives and electrical drives.
Coupled with the ability to change roll spacing readily
~3~'7
-32-
through fine pitch adjusting screws, there is available
an almost infinite selection of machine conditions to
control application of mixes to fabrics and yarns.
