Patent Application
20220235505
This application relates to a compactor for lengthwise compressive shrinkage of fabrics and specifically for a compactor with infeed and outfeed nip-points with gaps that dynamically adjust to a fabric's thickness.
Compactors for fabrics are generally either of a belt design type or a mechanical roller and shoe design type.
Belt design type compactors, while producing a good product, can be expensive and difficult to maintain. While most knitted fabrics require at least a 10% per compaction unit of compaction at finishing, felt belt type and rubber belt type compactors generally compact only about 5% per compaction unit, which is much less than mechanical roller type compactors. As a result, most belt type compactors require at least two compaction units in series, which increases their initial expense as well as their operation and maintenance expenses. In addition, belt type compactors usually operate at a maximum speed of forty meters per minute, about half the speed of mechanical roller type compactors, increasing production times and associated costs.
Mechanical roller and shoe design type compactors may operate at speeds and compaction rates higher than those of belt design type compactors. Mechanical roller and shoe design type compactors use heated rollers and heated shoes that pass a fabric to be compacted through narrow gaps that need to be slightly larger than the fabric's thickness. A fabric is compacted by reducing that fabric's speed as it exits the compactor through the narrow gap resulting in a lengthways shrinkage of that fabric. However, these narrow gaps are often difficult to maintain due to thermal warpage resulting from heat originating from the heated rollers and shoe. Further, these narrow gaps may be subject to variations resulting from the motion imparted during the compactor's operation. Also, fabrics that are compacted within a mechanical roller and shoe design type compactor may suffer from shine or glaze on one side of that fabric as a result of how the fabric is driven through the compactor.
What is needed is a compactor with the benefits of a mechanical roller and shoe design type compactor that eliminates the belt, dynamically adjusts their narrow gaps according to a fabric's thickness and minimizes the creation of shine and glaze on that fabric.
In an effort to address the above-described needs, a compactor for lengthwise compressive shrinkage of fabrics is disclosed. In some embodiment, the compactor for lengthwise compressive shrinkage of fabrics comprises an infeed roller rotating about an infeed center axis that is fixed and having an infeed outer surface, an outfeed roller rotating about an outfeed center axis that is fixed and having an outfeed outer surface, the infeed center axis and the outfeed center axis positioned parallel to one another as to define a compaction zone between the infeed roller and the outfeed roller, the compaction zone having a first longitudinal length and a first transversal width, a pressure roller rotating about a pressure center axis that is movable and having a pressure outer surface, the pressure center axis movable above the compaction zone as to be self-centering between the infeed roller and the outfeed roller and as to define an infeed nip-point between the infeed roller and the pressure roller and an outfeed nip-point between the outfeed roller and the pressure roller, and a saddle assembly within the compaction zone, the saddle assembly including a bed liner having an upper surface facing the pressure roller and a lower surface opposite the upper surface, the upper surface having a second longitudinal length that traverses a portion of the first longitudinal length and having a second transversal width that traverses a portion of the first transversal width.
In some embodiments, a method for lengthwise compressive shrinkage of fabrics is disclosed. The method for lengthwise compressive shrinkage of fabrics providing an infeed roller rotating about an infeed center axis that is fixed and having an infeed outer surface, providing an outfeed roller rotating about an outfeed center axis that is fixed and having an outfeed outer surface, positioning the infeed roller and the outfeed roller parallel to one another as to define a compaction zone between the infeed roller and the outfeed roller, the compaction zone having a first longitudinal length and a first transversal width, providing a pressure roller rotating about a pressure center axis that is movable and having a pressure outer surface, moving the pressure center axis above the compaction zone as to be self-centering between the infeed roller and the outfeed roller and as to define an infeed nip-point between the infeed roller and the pressure roller and an outfeed nip-point between the outfeed roller and the pressure roller, and providing a saddle within the compaction zone, the saddle assembly including a bed liner having an upper surface facing the pressure roller and a lower surface opposite the upper surface, the upper surface having a second longitudinal length that traverses a portion of the first longitudinal length and having a second transversal width that traverses a portion of the first transversal width.
The drawings described below are for illustrative purposes only and are not necessarily drawn to scale. The drawings are not intended to limit the scope of the disclosure in any way. Wherever possible, the same or like reference numbers are used throughout the drawings to refer to the same or like parts.
As mentioned above, this application relates to a compactor for lengthwise compressive shrinkage of fabrics and specifically to a compactor with infeed and outfeed nip-points with gaps that dynamically adjust to a fabric's thickness.
According to embodiments disclosed herein, the compactor for lengthwise compressive shrinkage of fabrics includes an infeed roller and an outfeed roller that are fixed to define a space between the infeed and outfeed rollers. The compactor further includes a pressure roller that is positioned between the infeed and outfeed rollers and is movable within the space defined between these rollers. An infeed nip-point is defined at a point where the pressure roller may come into contact with the infeed roller. An infeed gap is created at the infeed nip-point by a fabric that is being driven into the compactor. An outfeed nip-point is defined at a point where the pressure roller may come into contact with the outfeed roller. An outfeed gap is created at the outfeed nip-point by the fabric that is being driven out of the compactor. The size of the infeed gap and the outfeed gap is automatically adjusted to the fabric's thickness by the movement of the pressure roller within the defined space.
Individual variable-speed drives rotate each of the infeed, outfeed, and pressure rollers. Compaction of the fabric within the compactor is achieved by rotating the outfeed roller at a slower rate than the infeed roller. The actual rate of compaction is proportional to the difference in rotation speed between the infeed roller and the outfeed roller. The pressure roller is rotated at the same rate as the infeed roller to help minimize the creation of shine and glaze on the fabrics being driven through the infeed nip-point.
The infeed, outfeed, and pressure rollers may be heated to help increase the efficiency of the compactor. As a result of heating, slight thermal warpage of the infeed and outfeed gaps may occur. However, thermal warpage of the infeed and outfeed gaps is mitigated by the movement of the pressure roller in response to the fabric's thickness.
A saddle assembly may be positioned within a defined space between the infeed and outfeed rollers. The saddle assembly supports the fabric against the pressure roller as it traverses across a compaction zone within the defined space. The compaction zone encompassing an area between the infeed and outfeed nip-points and below the pressure roller in which the fabric is supported against the pressure roller.
The infeed roller 102 may be cylindrical with an infeed outer surface 110 that rotates about an infeed center axis 112. Similarly, the outfeed roller 104 may be cylindrical with an outfeed outer surface 114 that rotates about an outfeed center axis 116. The infeed center axis 112 and the outfeed center axis 116 are fixed to position the infeed and outfeed rollers 102, 104 parallel to one another within the same plane. The fixed positions of the infeed and outfeed centers axis 112, 116 define a gap 118 between the infeed and outfeed outer surfaces 110, 114 that is fixed.
The infeed and outfeed outer surfaces 110, 114 may be comprised of any durable material with appropriate frictional qualities known to one of ordinary skill in the art, including chrome-plated stainless steel. A thermal spray may also be applied to each of the infeed and outfeed outer surfaces 110, 114. The thermal spray providing a traction coefficient that is sufficient to drive and retard the movement of a fabric 120 through the compactor 100.
Specifically, the infeed outer surface 110 may have a first traction coefficient and the outfeed outer surface 114 may have a second traction coefficient. As will be apparent to a person of ordinary skill in the art, the first and second traction coefficients may be selected to accommodate a specific fabric type to be driven through the compactor 100. Moreover, as will also be apparent to a person of ordinary skill in the art, the first and second coefficients may be equal or different from one another.
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The pressure outer surface 122 may comprise any low friction and durable material known to one of ordinary skill in the art, including chrome-plated stainless steel. Also, a thermal spray may be applied to the pressure outer surface 122. The thermal spray provides a traction coefficient that is sufficient to drive and retard the movement of a fabric 120 through the compactor 100. Specifically, the pressure outer surface 122 may have a third traction coefficient. As will be apparent to a person of ordinary skill in the art, the third traction coefficient may be selected to accommodate a specific fabric type to be driven through the compactor 100. Moreover, as will also be apparent to a person of ordinary skill in the art, the third traction coefficient may be purposely equal to or different from the first and second traction coefficients.
A separate variable-speed drive may rotate each of the infeed center axis 112, the outfeed center axis 116, and the pressure center axis 124. Specifically, the infeed center axis 112 may be rotated by a first variable-speed drive 126, the outfeed center axis 116 may be rotated by a second variable-speed drive 128, and the pressure center axis 124 may be rotated by a third variable-speed drive 130.
Each of the variable-speed drives rotates a center axis to provide a surface speed to a corresponding outer surface. Specifically, the first variable-speed drive 126 may rotate the infeed center axis 112 to provide the infeed outer surface 110 a first surface speed. Similarly, the second variable-speed drive 128 may rotate the outfeed center axis 116 to provide the outfeed outer surface 114 with a second surface speed. Lastly, the third variable-speed drive 130 may rotate the pressure center axis 124 to provide the pressure outer surface 122 with a third surface speed.
To enable compaction of the fabric 120, the second surface speed of the outfeed outer surface 114 is less than the first surface speed of the infeed outer surface 110.
The rate of compaction is proportional to the difference in the first surface speed of the infeed roller 102 and the second surface speed of the outfeed roller 104. In an exemplary embodiment, the second surface speed of the outfeed roller 104 is twenty-five percent less than the first surface speed of the infeed roller 102. This results in a compaction rate of approximately twenty-five percent.
The third surface speed of the pressure outer surface 122 may be the same as the first surface speed of the infeed outer surface 110 of the infeed roller 102. This ensures that there is no or minimal rubbing of any surface of the fabric 120 that would create a shine or glaze on either side of the fabric 120.
Because the third surface speed is equal to the first surface speed, the third surface speed of the pressure outer surface 122 will also be different than the second surface speed of the outfeed outer surface 114 of the outfeed roller 104. As with the difference between the first and second surface speeds, the difference between the third surface speed of the pressure outer surface 122 and the second surface speed of the outfeed outer surface 114 is proportional to the rate of compaction. To minimize the creation of shine or glaze on the pressure roller 106 side of the fabric 120, the third traction coefficient of the pressure outer surface 122 is selected to be sufficiently low to prevent the creation of a shine or haze on the pressure roller 106 side of the fabric 120. The specific value of the third traction coefficient may be dependent on the type of fabric being compacted.
The infeed and pressure rollers 102, 106 may be heated to a nominal temperature. In an exemplary embodiment, the infeed and pressure rollers 102, 106 are heated to a nominal temperature by circulating hot oil through each of the infeed and pressure rollers 102, 104. Any other means of heating the infeed and pressure rollers 102, 106 to a nominal temperature known to a person of ordinary skill in the art may be implemented while remaining within the scope of the present disclosure.
The nominal temperature may be in a range of temperatures that will prevent a substantial heat transfer from a preheated fabric to the infeed roller 102 and the pressure roller 106. In an exemplary embodiment, the nominal temperature may be maintained generally around 180 degrees Fahrenheit.
The saddle assembly 108 may be positioned within the gap 118 between the infeed and outfeed roller 102, 104. Within the gap 118, the saddle assembly 108 is positioned proximate to the pressure roller 106 to help support the fabric 120 against the pressure outer surface 122 as the fabric 120 traverse across the gap 118.
A heater 132 may be positioned within the path of the fabric 120. The heater 132 functioning to heat the fabric 120 before it enters into the compactor 100 across the infeed roller 102 and the pressure roller 106. The heater 132 may heat the fabric using any reasonable means known to one of ordinary skill in the art, including electric-based heat, steam-based heat, and circulating oil-based heat. The fabric 120 is heated upon its entry into the compactor to help lubricate the threads of the fabric 120 and make them more pliable during compaction within the compactor 100.
The infeed roller 102 and the pressure roller 106 may combine to form an infeed nip-point 202. Specifically, the infeed nip-point 202 may be formed in an area where the infeed outer surface 110 may come into contact with the pressure outer surface 122 once the pressure roller is self-centered between the infeed and outfeed roller 102, 104.
Similarly, the outfeed roller 104 and the pressure roller 106 may combine to form an outfeed nip-point 204. Specifically, the outfeed nip-point 204 may be formed in an area where the outfeed outer surface 114 may come into contact with the pressure outer surface 122 once the pressure roller is self-centered between the infeed and outfeed roller 102, 104.
An infeed gap 206 is created at the infeed nip-point 202 by the fabric 120 positioned between the infeed outer surface 110 and the pressure outer surface 122. Similarly, an outfeed gap 208 is created at the outfeed nip-point 204 by the fabric 120 positioned between the outfeed outer surface 114 and the pressure outer surface 122.
The movement of the pressure roller 106 provides for the infeed and outfeed gaps 206, 208 to have a size determined by the thickness of the fabric 120 currently traversing through the infeed and outfeed nip-points 202, 204.
As discussed above, the pressure roller 106 is movable in a shown general direction 210 to allow it to self-center itself between the infeed and outfeed outer surfaces 110, 114. This movement of the pressure roller 106 in the shown general direction 210 further allows the infeed and outfeed gaps 206, 208 to automatically adjust their size to accommodate for the thickness of the fabric 120 currently traversing through the infeed and outfeed nip-points 202, 204.
A compaction zone 212 defines that portion within the gap 118 where the fabric 120 may be in contact with the pressure outer surface 122. The compaction zone 212 has a first transversal width 214 spanning a length between the infeed and outfeed nip-points 202, 204 and a first longitudinal length 216 spanning a longitudinal length of the pressure roller 106.
To ensure the proper creation of the infeed and outfeed nip-points 202, 204, a diameter of the pressure roller 106 is greater than the first transversal width 214 of the compaction zone 212.
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The upper surface 220 has a second transversal width 224 and a second longitudinal length 226 that each may be customized to accommodate the dimensions of the fabric 120 to be driven through the compactor 100. Specifically, the second transversal width 224 may traverse a portion or all of the first transversal width 214 of the compaction zone 212. Similarly, the second longitudinal length 226 may traverse a portion or all of the first longitudinal length 216 of the compaction zone 212.
The flexible bed liner 302 may be formed of any flexible material known to one of ordinary skill in the art that is both spring-like and heat resistant, including stainless steel, bronze, and plastic. The transversal edges 306 of the flexible bed liner 302 are profiled to sit flush against and ride along on the infeed and outfeed outer surfaces 110, 114.
The flexible bed liner 302 is sufficiently spring-like to bend into a concave form under the weight of the pressure roller 106 while it is self-centered between the infeed and outfeed rollers 102, 104. Once the pressure roller 106 is moved away from between the infeed and outfeed roller 102, 104, the flexible bed liner 302 may return to its original relaxed form. While the flexible bed liner 302 is concave, the upper surface 308 of the flexible bed liner 302 conforms itself to the convex shape of the pressure outer surface 122.
Moreover, the flexible bed liner 302 is sufficiently heat resistant to withstand heat originating from the infeed and outfeed rollers 102, 104 once they have been heated to the nominal temperature. Similarly, the flexible bed liner 302 is sufficiently heat resistant to withstand heat originating from a preheated fabric pressed against the upper surface 308 by the pressure outer surface 122.
A rib 310 may be coupled to the lower surface 312 of the flexible bed liner 302. The rib 310 extends downward from the lower surface 312 into an insert 314 within the saddle 304. The rib 310 may extend along the full length or only a portion of the second longitudinal length 226 of the flexible bed liner 302.
The rib 310 may be comprised of any rigid material known to one of ordinary skill in the art, including stainless steel, bronze, and plastic.
The rib 310 is shaped and dimensioned to move freely in a shown vertical direction 316 within the insert 314 as the flexible bed liner 302 bends and retracts in response to the position of the pressure roller 106. While allowing free movement of the rib 310 in the shown vertical direction 316, the placement of the rib 310 within the insert 314 helps restrict the movement of the flexible bed liner 302 in a shown horizontal direction 318. This restriction of movement in the shown horizontal direction 318 helps ensure that the flexible bed liner 302 remains centered between the infeed and outfeed roller 102, 104.
The saddle 304 may be comprised of any rigid material know to a person of ordinary skill in the art, including stainless steel and plastic. The saddle 304 may be secured to an adjacent fixture such as a frame member, floor, or wall to prevent movement of the saddle 304.
Each of the saddle strips 402 may run along the full or a portion of the second longitudinal length 226 of the flexible bed liner 302. Each of the saddle strips 402 may extend along a portion of the second transversal width 224, such as not to impede the flexibility of the flexible bed liner 302.
Moreover, each of the saddle strips 402 may have an elongated profiled edge 404 in a manner similar to the transversal edges 306 of the flexible bed liner 302. As with the profile edges of the 306 of the flexible bed liner 302, the elongated profiled edges 404 sit flush against and ride along on the infeed and outfeed outer surfaces 110, 114. The elongated profiled edges 404 help to further minimize movement of the flexible bed liner 302 in the shown horizontal direction 318.
The saddle strips 402 may be comprised of any material known to a person of ordinary skill in the art to be rigid and heat resistant, including stainless steel, bronze, and plastic.
The rigid bed liner 502 may be formed of any material known to a person of ordinary skill in the art that is both rigid and heat resistant, including stainless steel, bronze, and plastic. The transversal edges 506 of the rigid bed liner 502 are profiled to sit flush against and ride along on the infeed and outfeed outer surfaces 110, 114. The transversal edges 506 of the rigid bed liner 502 have a sufficient depth to help minimize movement in a shown horizontal direction 508 while the rigid bed liner 502 is positioned between the infeed and outfeed roller 102, 104.
The rigid bed liner 502 has an upper surface 510 that has been machined to conform to the shape of the pressure outer surface 122.
The rigid bed liner 502 is sufficiently heat resistant to withstand heat originating from the infeed and outfeed rollers 102, 104 once they have been heated to the nominal temperature. The rigid bed liner 502 is also sufficiently heat resistant to withstand heat from a preheated fabric pressed against the upper surface 510 by the pressure outer surface 122.
A rib 512 may be coupled to the lower surface 514 of the rigid bed liner 502. The rib 512 extends downward from the lower surface 514 into an insert 516 within the saddle 504. The rib 512 may extend along the full or a portion of the second longitudinal length 226 of the rigid bed liner 502.
The rib 512 may be comprised of any rigid material known to a person of ordinary skill in the art, including stainless steel, bronze, and plastic. The rib 512 is shaped and dimensioned to fit securely within the insert 516. The rib 512 within the insert 516 helps to further restrict the movement of the rigid bed liner 502 in the shown horizontal direction 508. This restriction of movement in the shown horizontal direction 528 ensures that the rigid bed liner 502 remains centered between the infeed and outfeed roller 102, 104.
The saddle 504 may be comprised of any rigid material know to a person of ordinary skill in the art, including stainless steel and plastic. The saddle 504 may be secured to an adjacent fixture such as a frame member, floor, or wall to prevent movement of the saddle 504.
In this embodiment, the flexible bed liner 602 further includes a plurality of holes 610. The plurality of holes 610 running along a portion of the full longitudinal length of the flexible bed liner 602 on each side of saddle 604 and is positioned between the saddle 604 and the saddle strips 606.
The plurality of holes 610 allows for the application of steam onto a fabric positioned on the flexible bed liner 612, the steam having been injected into the compaction zone from beneath the flexible saddle assembly 600.
Any reasonable means of generating and injecting steam into the compactor zone from beneath the flexible saddle assembly 600 known to a person of ordinary skill in the art may be implemented while staying within the scope of the present disclosure.
In this embodiment, the rigid bed liner 702 includes a pair of embedded channels 706 embedded within the rigid bed liner 702 on each side of the saddle 704 and running along a portion of the full longitudinal length of the rigid bed liner 702. The rigid bed liner 702 further includes a plurality of holes 708 running along a portion of the full longitudinal length of the rigid bed liner 702 on each side of saddle 704 and positioned above each of the embedded pair of embedded channels 706.
The pair of embedded channels 706 allows for the channeling of steam through the rigid bed liner 702.
The plurality of holes 708 allows for the application of steam onto a fabric positioned on the rigid bed liner 702, the steam having been injected into and distributed down each of the pair of embedded channels 706.
The foregoing description discloses only example embodiments. Modifications of the above-disclosed assemblies and methods which fall within the scope of this disclosure will be readily apparent to those of ordinary skill in the art.
This disclosure is not intended to limit the invention to the particular assemblies and/or methods disclosed, but, to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the claims.
