Patent Application
20220178070
The present invention relates to a manufacturing method for manufacturing a cotton-containing product.
In recent years, in the cotton agriculture, development and streamlining have been tried in, e.g., a cultivating method, or improvement, research and development of seeds, to increase the production of cotton. The basic material of produced cotton is fibers comprising cellulose, but it contains first impurities such as dirt and a minute amount of oil that adhere before it is harvested as a plant. Therefore, the color of cotton is not white but brownish. If these impurities remain, when dyeing a cotton product formed of cotton, the impurities repel the dye, thus making it difficult to dye the cotton product as desired.
Therefore, when processing fibers including cotton, it is necessary to dye the fibers after whitening the fibers by removing the above impurities. Specifically, a knitted cloth or a woven cloth is manufactured by using spun raw threads, and is refined and bleached in a dyeing factory equipped with discharged water treating facilities and water supply environment, thereby obtaining a greige before sewn.
Specifically, as a general method, spun threads formed into a “skein shape” are refined, bleached and dyed in a package dyeing machine or a hank dyeing machine, or spun threads formed into a “cheese shape” are refined, bleached and dyed in a package dyeing machine. In some cases, in order to reduce costs, refining and bleaching are performed in a package dyeing machine, and dyeing is performed in a hank dyeing machine.
When dyeing threads for jeans, a rope dyeing machine is often used with the threads bundled together. However, the threads are often refined and bleached in thread form by using a package dyeing machine.
For example, the below-identified Patent Document 1 proposes a processing method by which, when refining and bleaching a cotton cloth, second impurities applied in thread spinning, spinning, weaving, knitting steps are removed, too. The below-identified Patent Document 2 proposes a chemical agent treating method when performing glue removal and refining to fabrics. Also, in some cases, a method is used by which raw threads are refined and bleached in thread form, and then are kitted and woven, thereby obtaining a pre-sewn greige.
However, a large amount of water resources is consumed in the above refining and bleaching steps. While, during the manufacturing steps of cotton products, including the dyeing step, a large amount of water resources is required and consumed, the amount of water resources used for bleaching and refining among these accounts for as high as 70 to 80% of the total amount of water resources used to manufacture cotton products. Since a huge amount of water resources is consumed to manufacture cotton products, there are many countries and regions where cotton products cannot be manufactured from home-grown cotton. This is one of the main reasons why the cotton textile industry is shifting from many countries where the cotton agriculture has developed to other developing countries.
However, in developing countries, a situation often occurs where water resources are not sufficiently purified after use. Therefore, manufacturing cotton products could lead to worsening of the environment of developing countries.
It is an object of the present invention to reduce the amount of water resources consumed when manufacturing cotton-containing products, thereby protecting the environment of the respective countries and thus the global environment.
In order to achieve the above object, in the present invention, a cotton material is refined and bleached in the state of a sliver.
The “sliver” is an aggregate of fibers formed in a strip shape or a rope shape before twisting the cotton into threads. Since, in this sliver state, the individual fibers have not been entangled and have been separated compared to twisted threads, chemical agents and water used for refining and bleaching easily infiltrate into the individual fibers. Therefore, it is possible to significantly reduce the amount of consumed water compared to conventional methods in which twisted threads or fabrics are refined and bleached.
Also, in the present invention, when the refining and the bleaching are each performed in the sliver state, heating may be performed with steam. Since, in the sliver state, the individual fibers are exposed to the atmosphere, unlike twisted threads or fabrics, steam is easily applied to the individual fibers without being interrupted by the adjacent fibers. Therefore, after immersion in chemical agents used for refining and bleaching, the heating of the individual fibers with steam is smoothly performed without being hindered by the adjacent fibers, and can be easily performed at a high temperature to such an extent that the above chemical agents sufficiently act on the fibers. Also, since steam has a very low specific gravity compared to liquid water, compared to heating, in a hot water bath, for refining and bleaching, it is possible to significantly reduce the amount of consumed water resources by using steam for heating. Also, compared to conventional methods in which a hot water bath is used, and thus a large amount of water needs to be heated, since the mass of steam is significantly small compared to its volume, it is possible to significantly reduce the amount of energy required and consumed for heating with steam.
Also, in the present invention, when steam is applied to the sliver, the sliver may be refined and bleached while being arranged in a sheet shape. The sliver has not been twisted yet, but, if the sliver is gathered in a rod shape, it may be difficult to apply steam to the center of such a sliver. In contrast thereto, if the sliver is arranged in a sheet shape, all of the fibers constituting the sheet-shaped sliver are exposed, so that it is possible to save the amount of consumed steam and the amount of heat required for creating steam. Also, since slight friction is generated between the adjacent fibers of the sheet-shaped sliver, and the sheet-shaped sliver is kept wet by a chemical liquid, steam, etc., the sheet-shaped sliver can be sequentially processed as a continuous sliver sheet while being conveyed.
Also, in the present invention, after the sliver sheet is heated by applying steam to the sliver sheet, the sliver sheet may be washed while being conveyed by at least one perforated conveying medium. Since the sliver has not been twisted unlike threads, if the sliver is pulled strongly in its length direction, the sliver is likely to be separated, and thus it is difficult to convey the sliver while being pulled like threads. By washing the sliver while being placed on the at least one perforated conveying medium, it is possible to covey and wash the sliver constituting the sliver sheet, while applying little force to the sliver. The at least one perforated conveying medium may be, e.g., a mesh conveyor.
The following may be adopted: The at least one perforated conveying medium comprises two perforated conveying media comprising inner and outer mesh conveyors, wherein a perforated drum is immersed in a washing liquid, wherein the inner conveyor is disposed inside of the sliver sheet, and the outer conveyor is disposed outside of the sliver sheet, and wherein the washing of the sliver sheet comprises sucking a washing liquid in the perforated drum while conveying the sliver sheet along an outer periphery of the perforated drum, with the sliver sheet sandwiched between the inner mesh conveyor and the outer mesh conveyor, and passing the sucked washing liquid from outside of the outer conveyor through the outer mesh conveyor, then through the sliver sheet, then through the inner conveyor, and then through the perforated drum.
By rotating the sliver sheet along the periphery of the perforated drum while being sandwiched between the perforated conveying media, it is possible to make a washing liquid pass through the sheet surface of the sliver sheet without applying a force which causes separation of the sliver sheet, and it is possible to save the space for washing. Also, by creating a negative pressure due to suction of the washing liquid in the perforated drum, it is possible to suck the washing liquid from outside of the mesh conveyors sandwiching the sliver sheet to be rotated along the outer periphery of the perforated drum, thereby making it possible to wash the sliver sheet while generating a constant liquid flow. Also, by circulating a portion of the sucked washing liquid to the outside of the mesh conveyors in a water tank storing the perforated drum, it is possible to reduce the amount of consumed washing liquid. In a conventional general washing method, an object is washed by bending and lifting up the object for water replacement in washing tanks, and the washing efficiency depends on how many times the object is bent and lifted up, and the number of used washing machines. If such a conventional method is used, a large number of washing machines will be required, and also the sliver may be cut during processing in the bending and lifting up step. In contrast thereto, by adopting a suction type as described above, and washing the sliver sheet while being sandwiched between, and conveyed by, the conveying media, it is possible to further reduce the risk of sliver cutting. Also, while the above conventional washing method requires a large number of long and large washing machines, in the present invention, since the sliver sheet is moved along the perforated drum, it is possible to significantly shorten the space required for the water tank, and thus to significantly reduce the amount of consumed water and the size of a required factory site, compared to using the conventional method.
After the bleaching is finished, a function may be applied to the cotton material in the sliver state.
When applying functions to the fibers with various chemical agents, too, it is advantageous to do so in the sliver state, because this facilitates infiltration of the chemical liquids/agents and heating, and reduces the amount of consumed water resources, compared to applying functions in a hot water bath. The cotton sliver neutralized and washed with hot water after bleached is close to pure cellulose, and thus reacts quickly when applying a function thereto, thereby increasing work efficiency.
The sliver after bleached by the above method has been sufficiently whitened in the sliver state. By spinning this sliver, it is possible to obtain threads of which the individual fibers are sufficiently white. In a conventional method in which threads are first twisted, and then are refined and bleached, the inner portions of the threads are less likely to be effectively refined and bleached due to twisting; the threads need to be refined and bleached with a large amount of water; and thread portions which has not been sufficiently bleached tend to remain in the threads. For threads obtained from the sliver after refined and bleached according to the method of the present invention, since the threads have been refined and bleached without generating a disadvantage as described above caused by twisting, the individual fibers have been sufficiently processed, and thus the quality is good.
For the sliver of a cotton-containing material after bleached and refined according to the present invention, since the sliver has been already bleached and refined in the sliver state, it is possible to easily dye the sliver later. Also, since the sliver has been already refined, it is possible to easily obtain a textile product via various steps such as thread spinning, spinning and cloth weaving. At this time, since refining and bleaching, which tend to consume a large amount of water resources, have been already performed to the fibers in the sliver state, it is possible to significantly reduce the amount of water resources required for manufacturing cotton products. It is possible to obtain not only a 100% cotton product formed of threads spun from the above sliver, but also a cotton-containing product formed by blending together the above threads and threads made of a fiber other than cotton.
As a device for manufacturing a cotton-containing product by processing the sliver according to the present invention, a washing machine of a suction type may be used which comprises: a perforated drum immersed in a washing liquid; a suction device configured to suck the washing liquid from inside of the perforated drum; a pair of inner and outer mesh conveyors between which a sliver sheet is to be sandwiched; and a conveyor guiding device for conveying the sliver sheet along an outer periphery of the perforated drum, while sandwiching the sliver sheet between the inner mesh conveyor and the outer mesh conveyor, with the inner mesh conveyor disposed inside of the sliver sheet and the outer mesh conveyor disposed outside of the sliver sheet, wherein the suction device is configured to suck a washing liquid in the perforated drum, and pass the sucked washing liquid from outside of the outer mesh conveyor through the outer mesh conveyor, then through the sliver sheet, then through the inner conveyor, and then through the perforated drum, thereby washing the sliver sheet.
In other words, a production line for a cotton-containing product of a cotton material may be used wherein a refining step and a bleaching step are continuously performed on the cotton material, and wherein, in at least one of the refining step and the bleaching step, the production line includes: a steamer configured to heat a sliver sheet of the cotton material by applying steam to the sliver sheet after immersing the sliver sheet in a liquid; and the above-described washing machine of the suction type, which is configured to wash the sliver sheet after the heating.
According to the present invention, it is possible to significantly reduce the amount of water resources required for manufacturing cotton-containing products; reduce a burden on the environment; and manufacture cotton-containing products in more areas.
Regarding conventional refining and bleaching of batch type, threads after spun are refined for about 30 minutes in a refining liquid such as a surfactant, an enzyme agent or an alkaline agent, and then are bleached for 60 to 90 minutes in the same bath with, e.g., a surfactant, caustic soda or hydrogen peroxide. If caustic soda is used for bleaching, a lot of water and strong neutralizing acid (sulfuric acid) are required for washing and neutralizing this high alkalinity. This increases the amount of discharged processing water, and increases the burden of discharged processing water due to the its quality deterioration. Also, strong acid tends to damage the device. Regarding refining and bleaching continuously performed to a sliver, the use of strong alkali is not required; bleaching reaction can be completed in about 3 to 8 minutes; and refining reaction can be completed in 5 minutes or less. Such a manufacturing method is excellent in that it also can reduce processing time. Also, such a manufacturing method can reduce the amount of energy required for heating water, and reduce even a factory space required for processing. As a result thereof, it is possible to construct a small textile factory of which the burden on the environment is small, even in areas where it was difficult to construct a textile factory, thereby making it possible to vitalize the textile industry.
The present invention is described below in detail.
The present invention relates to a manufacturing method for manufacturing a cotton-containing product using a cotton material, and a cotton-containing product manufactured by this manufacturing method. The “cotton-containing product” refers to both a pure cotton product and a product containing cotton and another fiber. The present invention is particularly suitable for a pure cotton product.
The cotton material used in the present invention comprises a fiber or fibers including cotton. Not only a 100% cotton material but also blended and spun fibers comprising cotton and another fiber can be used. Specifically, such blended and spun materials include:
a cotton-and-Cannabis sativa-blended-and-spun material formed by blending and spinning cotton and Cannabis sativa such as ramie, linen or hemp;
a cotton-and-wool-blended-and-spun material formed by blending and spinning wool and cotton;
a cotton-and-cashmere-blended-and-spun material formed by blending and spinning cashmere and cotton;
a cotton-and-animal hair-blended-and-spun material formed by blending and spinning cotton and another animal hair;
a cotton-and-silk-blended-and-spun material formed by blending and spinning silk and cotton;
a cotton-and-regenerated cellulose fiber-blended-and-spun material formed by blending and spinning cotton and a regenerated cellulose fiber, e.g., lyocell such as Tencel (registered trademark), cupra (copper ammonia rayon), polynosic, rayon, or bamboo rayon; and
a cotton-and-synthetic fiber-blended-and-spun material formed by blending and spinning cotton and a synthetic fiber such as acetate fiber, nylon fiber or acrylic fiber.
In the present invention, a cotton material is processed in the state of a sliver, which is an aggregate of fibers before being twisted into threads. Specifically, the sliver is refined to remove dirt and oil components attached to the cotton, and bleached to whiten the brownish color. Basically, the bleaching is performed after the refining. Since the fibers are not sufficiently entangled in the sliver state, they will be disentangled when a strong force is applied thereto. Therefore, in the present invention, the sliver is preferably processed while being conveyed by a perforated conveying medium (or media) having holes. Such conveying perorated media include, e.g., a net, a group of chains, and a plate having holes in its plate surface. If a net is used, its meshes act as the holes. If a chain conveyor is used which comprises chains connected together on a plane, the holes of the individual rings, and the gaps between the respective rings act as the “holes”. As a plate having holes, for example, individual blocks constituting the conveyor and each having holes in its plate surface can be used, or a cylindrical plate constituting a cylindrical drum, and having holes in its peripheral surface can be used.
In the present invention, the slivers are processed while being placed on such a conveying medium. Instead of a single conveying medium, a plurality of conveying media may be used alternately, or the slivers may be sandwiched between a plurality of conveying media. When placing the slivers onto a conveying medium, the slivers are preferably arranged into sheets. The sliver arranged in a sheet shape is referred to as “sliver sheet”. By arranging the sliver in a sheet shape, it is possible to handle the sliver as a single aggregate due to the friction between the individual fibers constituting the sliver, thus enabling the sliver to have a strength required when conveyed and processed. This prevents separation of the individual fibers even when subjected to steam or a liquid flow as described later.
First, the sliver is taken out of a supply source 11, and arranged in a sheet shape to form a sliver sheet. In terms of work efficiency, the sliver sheet is preferably a seamless, continuous sheet. The sliver sheet formed by arranging the sliver in this way is continuously placed onto the above conveying medium, and refined in a refining step 12. In the refining step 12, foreign objects included in the raw cotton, such as plant leaves and stems, and other undesired objects such oils and fats, and other impurities, are removed before the next bleaching step 13. After the refining step 12, the sliver sheet is sequentially introduced into the bleaching step 13 as it is. In the bleaching step 13, color components which look yellow or brown mainly derived from the original color of the cotton are removed to whiten the fibers. After the bleaching step 13, a post-processing step 14 is, if necessary, performed, and a bleached sliver of which the individual fibers have been refined and bleached thoroughly is obtained. After a spinning step 15 where the bleached slivers are spun, threads are obtained as the cotton product.
As the above sliver supply source, the Kens method may be used or the wrapping method may be used. Also, in the first place, the sliver per se is obtained by arraying and bundling raw cotton by use of a carding machine. The sliver bundled in a strap shape may be developed into a sheet shape later, or the sliver may be developed into a sheet shape from the beginning. Fibers bundled together to constitute a continuous sliver of cotton material are developed into a sheet shape within the width range of the conveying medium located within the widths of the machines used in the subsequent steps, thereby sequentially forming the continuous sliver sheet. The sequentially formed continuous sliver sheet is then sequentially processed in the above-described steps. In order to assist in this conveyance of the continuous sheet, the forming speed at which the continuous sliver sheet is formed needs to be equal to, or faster than, the processing speeds in the subsequent steps. However, since the sliver or the sliver sheet needs to be pulled until it is placed onto the conveying medium, it is necessary to adjust the tensile load so as to prevent disentanglement of the slivers.
An exemplary production line where the refining step 12 to the post-processing step 14 are continuously performed on the continuous sliver sheet is shown in the plan view of
First, the refining step 12 is described. In the refining padder 21, a liquid immersion sub-step 12a is perform as a preparation part of the refining step 12. The refining padder 21 is configured to receive the continuous sheet-shaped sliver sheet 51 on an inwardly inclined receiving seat located at a lower portion of its injection port. The refining padder 21 is further configured to send the continuous sliver sheet 51 received on the receiving seat to a refining liquid immersion portion 21a. When sending the sliver sheet into the portion 21a, and feeding it within the devices, a conveying medium such as a mesh conveyor is used which can convey the continuous sliver sheet 51 while being placed on the conveying medium. The refining padder 21 is further configured to squeeze, in a pressure applying mangle device 21b, the continuous sliver sheet to which a refining liquid was applied at the refining liquid immersion portion 21a, and then feed it out of the refining padder 21. The liquid immersion sub-step 12a does not particularly require heating, and can be performed at normal temperature (room temperature). The refining liquid is stored in the refining liquid immersion portion 21a, and the continuous sliver sheet 51 is immersed in the refining liquid at a speed of, approximately, not less than 5 m/minute to 10 m/minute. In a general refining step for refining threads, about four to five liquid tanks for storing a refining liquid are prepared, and threads are continuously immersed in these liquid tanks to infiltrate the refining liquid into the fibers, or threads are processed for a long time with a high-temperature chemical liquid. This is because cotton fibers are covered with oil and fat, or pectin, and thus water-repellent, i.e., do not absorb water. In contrast, in the present invention, since the continuous sliver sheet 51 is immersed in the refining liquid, and the individual fibers are entangled weakly in this state, even though the continuous sliver sheet is water-repellent, it is possible to sufficiently infiltrate the refining liquid into the individual fibers by immersing the sliver sheet only once.
The above refining liquid has weak acidity, and preferably has a pH of about not less than 3.0 and not more than 5.5. The above refining liquid preferably contains, in addition to the acid components, an acid-resistant penetrant, an enzyme catalytic agent, a degassing penetrant, etc. The enzyme catalytic agent is a chemical agent enabling effective refining under the high-temperature conditions in the next steam heating sub-step 12b. The degassing penetrant promotes replacement of air contained in the slivers with the refining liquid. Since the degassing penetrant quickens infiltration, by using the degassing penetrant, it is possible to omit, for example, a pre-washing tank and a chemical application tank, and thus to reduce the amount of water required for the processing.
The roll-squeezing conditions of the pressure applying mangle device 21b, which is located on the exit side of the liquid immersion sub-step 12a, are preferably about 70 to 100%. However, the continuous sliver sheet needs to be kept wet to some extent. In a wet state, the continuous sliver sheer has a strength enough to be able to maintain its shape in the subsequent processing, too, due to the friction between the individual fibers. Preferably, the sliver sheet is conveyed by the above conveying medium until immediately before being sandwiched between the upper and lower rolls, and conveyed again on the same conveying medium right after being squeezed by the rolls.
Next, in a refining steamer 22, the steam heating sub-step 12b is performed to heat the continuous sliver sheet 51 to which the refining liquid has been applied. Refining reaction is advanced by steam filling the interior of a steamer tank into which the continuous sliver sheet 51 with the refining liquid is sent. The temperature of the interior of the steamer tank 22a is preferably about not less than 98° C. and not more than 105° C. If this temperature is too low, the steam will condense, so that heat transfer may be insufficient. On the other hand, if the above temperature is too high, an unexpected reaction may occur. The reaction time in the steamer tank is preferably about not less than 1 minute and not more than 5 minutes. The steam pressure of the introduced steam is preferably about not less than 0.3 MPa and not more than 0.7 MPa. Since the continuous sliver sheet 51 has been squeezed by the pressure applying mangle device 21b, although the surface of the continuous sliver sheet 51 is wet, little water is present on the surface. Therefore, molecules of steam, which are sufficiently smaller than liquid waterdrops, easily come into contact with the individual fibers, and quickly supplies a sufficient amount of heat to heat the fibers, thereby making it possible to advance the refining reaction in a short time. In order to easily apply steam to the entire continuous sliver sheet 51, the conveying medium for conveying the sliver sheet 51 preferably has holes through which steam passes, as with a mesh conveyor.
Next, in a washing machine 23, a washing sub-step 12c is performed to wash off the refining liquid that remains adhered to the continuous sliver sheet 51 after the reaction.
Preferably, the continuous sliver sheet 51 is washed in the washing machine 23, while being conveyed by a conveying medium having holes. If individual sliver sheets are independently immersed in a washing liquid, they could be disentangled. However, by placing the continuous sliver sheet on a conveying medium having holes, or by sandwiching the sheet 51 between conveying media having holes, it is possible to continuously wash a large amount of sliver while preventing disentanglement of, and damage to, the slivers.
Especially in order to continuously wash the continuous sliver sheet 51 without damaging the sliver sheet 51, by using inner and outer mesh conveyors 53a and 53b as the conveying media having holes; and immersing the continuous sliver sheet 51 in the liquid, thus exposing the sliver sheet 51 to a liquid flow, with the sliver sheet 51 sandwiched between the inner and outer conveyors 53a and 53b, it is possible to wash the continuous sliver sheet 51 while protecting the sliver sheet 51 by the conveyors on both sides thereof.
As the washing machine 23, a normal washing machine can be practically used. However, by using a washing machine 50 of the liquid suction type, it is possible to maximize the advantage of washing the fibers in the form of the continuous sliver sheet 51. A single washing machine of the liquid suction type can produce a washing effect roughly comparable to the washing effect of three to four general washing machines of the replacement type. Since the individual fibers of the continuous sliver sheet 51 are not twisted together, it is possible to wash the individual fibers quickly by liquid suction. Also, by liquid suction, it is possible to wash the sliver sheet with a small amount of washing liquid, compared to washing in a static liquid, and thus to reduce the amount of water used. In a conventional arrangement in which threads or fabrics are continuously washed in a static liquid, a long and large tank is required for washing. By using the washing machine 50 according to the present invention, it is possible to use a compact tank, and realize an energy-saving factory, i.e., significantly reduce both the consumption of water and the area of land occupied.
The washing machine 50 of the liquid suction type includes a perforated drum 57 having holes and immersed in a washing liquid; and a suction device for sucking the washing liquid from inside of the perforated drum 57. The washing machine 50 further includes a conveyor guiding device for conveying the continuous sliver sheet 51 along the outer periphery of the perforated drum 57 with the continuous sliver sheet 51 sandwiched between the inner conveyor 53a located inside of the continuous sliver sheet 51 and the outer conveyor 53b located outside of the continuous sliver sheet 51.
The washing machine 50 of the suction type, which includes the above-described suction device and conveyor guiding device, is now described while exemplifying its specific embodiment.
The continuous sliver sheet 51 is introduced into the washing machine 50 while being placed on a conveying medium or media. In the embodiment, conveying media comprising two chain conveyors (inner and outer conveyors 53a and 53b) are used. After washing the continuous sliver sheet 51 while being sandwiched between the inner and outer conveyors 53a and 53b, the continuous sliver sheet 51 is fed while being placed on the outer conveyor 53b to a pressure applying mangle device 52 and squeezed by the mangle device 52 to remove excess liquid.
The continuous sliver sheet 51 conveyed from the upper left side of
The above conveyor guiding device is configured to guide the conveyors such that the continuous sliver sheet 51 is continuously conveyed along the outer periphery of the perforated drum 57. The conveyor guiding device is constituted by a plurality of rollers, described later, which are disposed such that (i) the continuous sliver sheet 51 is sandwiched between a portion of the inner conveyor 53a and a portion of the outer conveyors 53b; (ii) the portions of the inner and outer conveyors between which the sliver sheet is not sandwiched are continuously moved; and (iii) the inner and outer conveyors and the sliver sheet are guided along the outer periphery of the perforated drum 57. Conveyor driving devices for driving the respective conveyors per se are preferably connected to some of these rollers.
The inner conveyor 53a moves along a loop path at the upper central portion of
The conveyor driving device for driving the inner conveyor 53a per se is configured such that the roller 72a is rotated by a driving roller 68 rotated by a motor 66 via a chain 69, thereby causing the entire inner conveyor 53a to move along a loop path. The roller 72a is not limited to the roller shown. By the mechanism for driving the inner conveyor 53a, and the below-described mechanism for driving the outer conveyor 53b, the continuous sliver sheet 51 sandwiched between the inner conveyor 53a and the outer conveyor 53b is rotated along the outer periphery of the perforated drum 57.
On the other hand, the outer conveyor 53b moves along a loop path extending inside and outside of the washing tank 54 as follows: The outer conveyor 53b is moved from the left in
The conveyor driving device for driving the outer conveyor 53b per se is configured such that the roller 71d is rotated by the driving roller 68, which is rotated by the motor 66 via the chain 69, thereby causing the entire outer conveyor 53b to move along the loop path. The roller 71d is not limited to the roller shown.
The continuous sliver sheet 51 is conveyed along the outer periphery of the perforated drum 57, while being sandwiched between the inner and outer conveyors 53a and 53b. By conveying the sliver sheet while being sandwiched between these conveyors, it is possible to reduce the possibility of the sliver being severed due to frictional resistance, contact resistance, etc. By introducing and discharging the continuous sliver sheet 51 while being sandwiched between the conveyors and rotated, the sliver, having a low specific gravity and likely to float in the processing liquid, can be sequentially submerged in the liquid, thus preventing cloth floating and improving infiltration of the liquid.
The inner and outer conveyors 53a and 53b are conveying media having holes through which a liquid flow can pass. The perforated drum 57, along which these conveyors are guided, also has, in its circumference, a plurality of holes through which a liquid flow can pass. Since the individual fibers of the continuous sliver sheet 51 are not twisted together, the continuous sliver sheet 51 per se has a structure in which the individual fibers are easily exposed to the liquid flow. The perforated drum 57 has a suction port 59 through which washing water is axially sucked from inside of the perforated drum 57 near its center. When washing liquid is sucked through the suction port 59 by the suction device, a negative pressure is generated in the interior of the perforated drum 57, and thus liquid in the washing tank 54 is sucked into the perforated drum 57, while passing through the outer conveyor 53b, the continuous sliver sheet 51, the inner conveyor 53a, and the perforated drum 57. By being exposed to this liquid flow, the continuous sliver sheet 51 is washed quickly. Since the continuous sliver sheet 51 is moved by the conveyors while being sandwiched therebetween, its displacement or contact movement does not occur. Therefore, it is possible to efficiently perform liquid replacement in the fibers, and thus to wash the sliver sheet extremely efficiently, compared to doing so in a simple washing machine.
After washing, the continuous sliver sheet 51 is squeezed by the pressure applying mangle device 52 so as to remove water, and then conveyed to the next step while being placed on the chain conveyor 53c.
Since water in the washing tank 54 is continuously discharged out of the system while being carried by the continuous sliver sheet 51, it is desirable to supply water into the tank 54 as necessary. Specifically, water sucked through the axially extending suction port 59 at the center of the perforated drum 57 is introduced into a pump 63 through a downwardly extending suction pipe 62. The pump 63 constitutes the suction device configured to suck water from inside of the perforated drum 57. The water is fed from the pump 63 into an upwardly extending discharge pipe 64, and is returned into the washing tank 54 from a spout 65 disposed above a predetermined water level, through the discharge pipe 64. On the other hand, the washed continuous sliver sheet 51 is fed into the next bleaching step 13 after removing excess water with the pressure applying mangle device 52 near the exit.
Next, the bleaching step 13 is described. In a bleaching padder 31, a liquid immersion sub-step 13a is performed as a preparation part of the bleaching step 13. The basic structure of the bleaching padder 31, and the basic system thereof comprising a bleaching liquid immersion portion 31a and a pressure applying mangle device 31b are the same as those of the above refining padder 21, in which the liquid immersion sub-step 12a is performed, and a bleaching liquid is adhered to the continuous sliver sheet 51 in the liquid immersion sub-step 13a. However, the bleaching liquid used here is different from the above refining liquid.
The above bleaching liquid is an alkaline liquid containing a bleaching agent, and preferably has a pH of about not less than 8.5 and not more than 11.0. Hydrogen peroxide water can be suitably used as the bleaching agent. The bleaching liquid preferably contains a penetrant which promotes wetting, because such a penetrant quickens infiltration of the chemical liquid, so that it is possible to omit, e.g., a pre-washing tank and/or a chemical liquid application tank, and thus to reduce the amount of water required for the processing. Further preferably, the bleaching liquid contains a hydrogen stabilizer and/or a reaction catalyst. As an alkaline agent for alkalinizing the bleaching liquid, for example, a chemical agent that shows weak alkalinity such as sodium carbonate can be suitably used.
The roll-squeezing conditions of the pressure applying mangle device 31b on the exit side of the liquid immersion sub-step 13a are preferably about 70 to 100%. However, the sliver sheet needs to be kept wet to some extent. In a wet state, the continuous sliver sheet has a strength enough to be able to maintain its shape in the subsequent processing, too, due to the friction between the individual fibers.
Next, in a bleaching steamer 32, a steam heating sub-step 13b is performed to heat, with steam in a steamer tank 32a, the continuous sliver sheet to which the bleaching liquid has been applied. The process in the steamer tank 32a can be performed under conditions similar to those of the process in the above steamer tank 22a. With the bleaching liquid applied, the continuous sliver sheet is fed into the steamer tank, and subjected to bleaching reaction by steam filling the interior of the steamer tank. While the reaction generated by the heated bleaching liquid is different from the reaction generated in the refining step 12, it is preferable that the structure and conditions of the device are basically the same as those of the corresponding device in the refining step 12. However, the reaction time in the tank of the bleaching steamer 32 is preferably about not less than 6 minutes and not more than 8 minutes. This reaction time is longer than the reaction time in the refining step, but can be significantly reduced to at most half or less, and in some cases to one-fourth or less, of the reaction time when conventional bleaching is performed in a hot water bath. Therefore, compared to conventional methods, it is possible to significantly reduce the consumption of energy or water required for bleaching which requires a processing load larger than refining requires.
Next, in a washing machine 33, a washing sub-step 13c is performed to wash off the bleaching liquid that remains adhered to the continuous sliver sheet after the reaction. By using a washing machine 50 of the suction type as in the above washing sub-step 12c, it is possible to quickly wash off the bleaching liquid without damaging the continuous sliver sheet 51, while reducing the amount of water required for washing.
Thereafter, the post-processing step 14 is performed. First, a neutralization sub-step 14a is performed in a neutralization paddler 41. Specifically, since the continuous sliver sheet 51 still has alkalinity due to the bleaching liquid even after the washing following the bleaching, the sheet 51 is neutralized in this sub-step. Thereafter, a hot washing sub-step 14b is performed in a hot water washing shower padder 42 to complete the sliver sheet.
During the post-processing step, or before or after the post-processing step, other function processes may be performed, such as a durability/softening process, a washing durability process, an antibacterial process, a quick-drying function process, a sweaty odor eliminating process, an aging odor eliminating process, and/or a water-repellent process.
Thereafter, though not shown, the sliver is preferably dried in the form of the continuous sliver sheet 51. In a wet state, the sliver sheet has a certain degree of strength due to increased frictional forces between the fibers, but this strength decreases after drying. Therefore, the sliver sheet is preferably dried while being placed on a conveying medium having holes. The dryer used for drying preferably has a structure which can prevent excessive dispersion of liquid due to the air volume, wind speed and wind pressure during drying. Hot air is blown out from the interior of the dryer to the upper and lower sides of the dried object. The wind outlet of the dryer preferably has a structure which allows hot air to easily pass through the gaps between the fibers of the continuous sliver sheet. The heat source required for drying may be steam, gas or an electric heater. It is preferable that the temperature of applied heat can be selectively changed between 70° C. and 180° C., depending on the material of cotton to be dried. As a result of fully drying the continuous sliver sheet, by the function of the dryer which can control wind pressure and wind volume, it is possible to obtain a continuous sliver sheet bulging like the shape of the continuous sliver sheet when injected.
In this way, it is possible obtain a bleached sliver, or a sliver to which the above functions have been applied by additional function processes. The obtained continuous sliver sheet is spun into threads (spinning step 15) after being formed into the shape of KGY slivers having a thickness of about 1 KGY. In order to form the continuous sliver sheet into the KGY slivers, either one of the following first and second methods may be selected. In the first method, as in a normal, raw cotton spinning step, the sliver sheet is processed in a blending and blowing machine, and then processed in a drawing frame via. e.g., a carding machine, thereby obtaining the KGY slivers for spinning. In the second method, individual slivers separated from the sliver sheet and each distributed as a single sliver are injected into a drawing frame as they are, thereby obtaining the KGY slivers for spinning. The KGY slivers formed by either of the first and second methods can be spun at a desired thickness into threads having a function according to the desired thickness. In the first method, more manufacturing steps and more time are required, thus increasing the cost. On the other hand, in the second method, since the processed slivers can be injected into a drawing frame as they are, it is possible to obtain spun threads in a short time without increasing the cost, and thus to streamline production. In the second method, since the sheet-shaped sliver after dried needs to be separated into the individual slivers by a sliver separating device, this device is preferably prepared beforehand as a sliver separating and distributing device so as to be additionally usable when required later.
In order to obtain a woven fabric and a practical product, after the steps in
Examples are described below in which refining and bleaching of slivers using steam according to the present invention were actually performed. Whiteness degree was evaluated using JIS whiteness degree and Hunter whiteness degree, and measured using a CR410 colorimeter of Konica Minolta. The results are shown in the following Table 1.
In the refining step using steam, refining was performed with refining liquids each containing chemical agents as shown in the below-inserted Table 2. These chemical agents are acid refining agent—chemist DN (produced by Satoda Chemical Industrial Co., Ltd.); acid-resistant penetrant—anizol MA-27 (produced by Satoda Chemical Industrial Co., Ltd.); enzyme catalytic agent—AC600 (produced by RAKUTO KASEI INDUSTRIAL CO., LTD.); and degassing penetrant—MAC-N2 (produced by Hokko Chemical Co., Ltd.). After the corresponding refining liquid was applied to each sliver by the refining padder at normal temperature, the sliver was treated with steam of 100° C. for 3 minutes, and washed by the washing machine of the suction type shown in
Batch refining was performed by immersion in a refining liquid. Specifically, an oven backet made of stainless steel to be placed into the cheese dyeing machine produced as a processing machine by HISAKA WORKS, LTD. and described in Japanese Patent No. 554172 was prepared, and a sliver was placed into this oven backet, and processed/treated for 30 minutes at a liquid temperature of 50° C. After washing the sliver, the sliver was bleached with steam, by use of the same chemical agents, and under the same condition, as used in bleaching in Example 1.
In both the Examples and the Comparative Example, bleaching was performed with steam. Specifically, a bleaching liquid was applied to the bleaching padder, and each sliver was treated for 3 minutes with steam of 100° C. Then, after squeezing the beaching liquid out from the sliver by use of the pressure applying mangle device on the exit side, the sliver was washed by the washing machine of the suction type shown in
The treatment time in steam refining was 3 minutes, whereas the treatment time in batch refining was 30 minutes. In steam refining, the amount of required treatment liquid is substantially equal to the amount of each processed sliver, whereas, in batch refining, the amount of required treatment liquid is about 10 times larger than the amount of the processed sliver. While, compared to steam refining, a lot of treatment time is required, and a large amount of processing liquid is discharged in batch refining, by using the present invention, it is possible to reduce the treatment time and the amount of discharged water, and thus to reduce required energy, a burden on the environment, etc. Also, the whiteness degree of each sliver refined with steam is higher than that of the sliver refined in batch form, and the whiteness degree of the sliver refined with steam using the degassing penetrant is higher than that of the sliver refined with steam without using the degassing penetrant, thus improving its actual quality, too.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-067094 | Mar 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/050296 | 12/23/2019 | WO | 00 |
