CA1098258A - Indigo dyeing process - Google Patents
Indigo dyeing processInfo
- Publication number
- CA1098258A CA1098258A CA297,106A CA297106A CA1098258A CA 1098258 A CA1098258 A CA 1098258A CA 297106 A CA297106 A CA 297106A CA 1098258 A CA1098258 A CA 1098258A
- Authority
- CA
- Canada
- Prior art keywords
- yarns
- dye
- oxidizing
- container
- passing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/22—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using vat dyestuffs including indigo
- D06P1/222—Oxidising agents
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B19/00—Treatment of textile materials by liquids, gases or vapours, not provided for in groups D06B1/00 - D06B17/00
- D06B19/0005—Fixing of chemicals, e.g. dyestuffs, on textile materials
- D06B19/0064—Fixing of chemicals, e.g. dyestuffs, on textile materials by a fixing bath
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B21/00—Successive treatments of textile materials by liquids, gases or vapours
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/22—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using vat dyestuffs including indigo
- D06P1/228—Indigo
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Treatment Of Fiber Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A process and a system for dyeing yarns with indigo dye is disclosed. Previous methods for dyeing yarns with indigo dye have included the necessity of forming multiple ends of yarn into a rope and passing the rope through a series of dye baths followed by an air drying or skying step. The present method avoids the necessity of forming a rope, and avoids the skying step. Yarn is continuously passed in sheet form at least once through an indigo dye solution and thereafter squeezed to remove excess dye solution. The dyed yarns are then passed through an oxidizing liquor to fix the dye to the yarns. The system includes a dye container, means for passing yarns through indigo dye solution in the container, squeezer means for removing excess dye solution from the yarns, an oxidizing container and a means for passing yarns through oxidizing liquor in the oxidiz-ing container.
A process and a system for dyeing yarns with indigo dye is disclosed. Previous methods for dyeing yarns with indigo dye have included the necessity of forming multiple ends of yarn into a rope and passing the rope through a series of dye baths followed by an air drying or skying step. The present method avoids the necessity of forming a rope, and avoids the skying step. Yarn is continuously passed in sheet form at least once through an indigo dye solution and thereafter squeezed to remove excess dye solution. The dyed yarns are then passed through an oxidizing liquor to fix the dye to the yarns. The system includes a dye container, means for passing yarns through indigo dye solution in the container, squeezer means for removing excess dye solution from the yarns, an oxidizing container and a means for passing yarns through oxidizing liquor in the oxidiz-ing container.
Description
8~
This invention relates to an improved process for dyeing yarn with an indigo dye, and a system ~or carrying ou*
the improved processO
Indigo dyes are partioularly suited in the prepara-tion of yarn used for jeans. The indigo dyes fade and faded jeans are in great consumer demandO It is preferred to dye the yarns in yarn form before weaving the yarns into cloth J
and in o~e presently known process of dyeing yarn in a con-tinuous proc0ss rather *han a batch process, multiple ends of yarn i~ sheet form are taken of~ a beam a~d formed in$o a rope, the yarn rope then passes over a series of rollers or pulleys which dip into an indigo dye bath, and then immediately into an air dryi~g or skying step which o~idizes the dye and fixes it in the yarns~ The dipping and skying steps are repeated until the desired shade of colour is obtained in the yarnO The yarn rope is then dried~ and in a separate process called rebeaming, the rope is transformed back into sheet form and rewound on a beam for weaVillg into a fabric used in making jeans This yarn dyeing process is quite slow however, because of the slow oxidizing step required after each immersio~
o~ the yarn rope into a dye bath~ Each skying step can, for e~ample, take up to two minutesO In addi$îon, the ~orma*ion of the yarn into a rope makes it difficult to u~iformly dye the yarns. The yarns in the middle of the rope may end up a lighter shade than the yarns on *he outside of the rope Furthermore, the process of starting with a sheet of yarns, forming a rope for the dyeing s-tep and then reforming a sheet is ine~ficient It is, therefore, a purpose of the present invention to provide an improved continuous process for dyeing yarn with an indigo dye whioh is faster than the known process and which provides a more uniform dyed productO It is also a purpose of the present invention to provide an indigo yarn dyeing process which avoids having to form a sheet of yarns into a rope for the dyeing step 7 and avoids the skying step after dipping in a dye bathO Thus, it is a purpose o~ the present invention to provide an indigo dyeing process which is simpler than the known process.
The present invention provides a process o~ dyeing yarns with indigo dye comprising the steps o~; continuously passing the yarns in sheet form at least once $hrough an indigo dye solution and thereafter squeezing the yarns to remove excess dye solution 9 and passing the dyed yarns through an oxidizing liquor to fix the dye to the yarns.
Preferably the yarn is passed through the system in sheet form rather than rope form thus further speeding up the process since the individual yarns are more accessible for treatment. In addition, the time and apparatus needed to form the yarn sheet into a rope, and from a rope back into sheet form, at the start and finish of dyeing are no$ needed since skying is no lo~ger required. Since the yarns are dyed in sheet form, they can be immediately sized a~ter dyeing and then wound on a loom beam ready ~or weaving thus providing further e-P~icienciesO
The invention is also directed toward a system for dyeing yarns ~ith indigo dye comprising a dye container ~or holding an indigo dye solution, means for passing yarns through the indigo dye solution in the dye container, squeezer -means for remo~ing excess dye solution from the yarns, an o~idizing container ~or holding oxidizing liquor -to fix the dye to the ~arns, means for passing yarns from the squeezer means through the oxidizing liquor in the oxidizing container.
The invention will now be described in detail having , re~erence to the accompanying drawing identi~ied as Figures la, lb and lc which illustrate schematically one embodiment o~ the improved system for indigo dyeing a plurality o~ yarns, The yarns to be,dyed are provided in sheet form 1 wound on beams 2 which can be rotatably supported on creels or stands 3. The yarns are drawn o~f the beams 2 still in sheet ~'orm, and passed through a wash box 4 for applying a heate~ wetting agent to the yarns. The yarns are cooled i~
eooling cabinet 5 and then passed through at least one but pre~erably two or three i ndigo dye baths 6. Aft0r each of the dye baths 6, the yarn sheet 1 is passed through a set of squeeze rolls 7 and a~ter the last squeeze rolls 7, the yarn sheet 1 passes through an oxidizing tank 8 which fixes the indigo dye in the yarns. The yarns are then washed in one or two wash tanks 9 and dried over drying cans 10. The yarn sheet 1 is then si~ed in a size bath 11 and dried over a second set o~ drying cans 12, The yarn sheet 1 is then wound on a loom beam 13 with the dyed yarns ready ~or weaving.
In more detail, a pair o~ ~irivell rolls 20, pull the sheet 1 from the beams 2, when~e it is passed under two carrier rolls 21 submer~ed in the wash box 4. In the embodi-ment shown multiple creels are used, each creel having 400 ends o-~ yarn. With twelve creels this gives a sheet havi~g 4800 ends o~ yarn. A pair of squeeze rolls 22 are mounted above the wash box 4 to squeeze excess liquid out of the yarn sheet 1 and return it t o the wa~h box 4. The wash box 4 holds a wetting agent liquid 23 which treats the yarn to allow it to more easily pick up dye, The wetting agent liquid 23 pr0~erably cvmprises a mi~ture o~ water, a wetting agent such as that known under the trade mark Levapon A,N., and caustic soda, pre~erably in the proportions o~ 65 gallo~s water, 2028 grams per litre o~ Levapon A,N., and 5047 grams per litre of caustic soda. The wet-ting agent liquid 23 pre~rably i~ maintained at a temperature o~ about 200F
by suitable heating means such as a clssed steam coll, (not shown). The squeeze rolls 22 are set at a pressure to leave about 50% liquid in the yarns based on the weight of the yarn~
After leaving the squeeze rolls 22, the yarn sheet l is passed over a carrier roll 24 and then enters the en-closed cabinet 5 which comprises upper carrier rolls 25 and lower carrier rolls 26 within the cabinet, an inlet 27 for the sheet at o~e side o~ the cabinet, an outlet 28 for the sheet at the other side o~ the cabinet, air inlets 29 in the body of -the cabinet 5 and an exhaust air outlet 30 at the top of the cabinet. The exhaust air outlet 30 has an exhaust ~an (not shown) to cause a circulation o~ air through the cabinet 5. The yarn sheet l passes through inlet 27 into cabinet 5. In the diagram the sheet is shown threaded between the first upper and first lower carriQr rolls 25, 26 within the cabinet 5 and then is passed over only the upper rolls 25, finishing o~ on the last lower and upper roll 26, 25 before exitîng fro~ outlet 28. In t'he embodiment shown, the majority of lower rolls 26 are not used, however, i~ greater cooling is required or higher sheet speeds are used, then the sheet may pass back and forwards ~rom upper to lower rolls.
Air passes through the inlets 29 in the cabinet 5 to cool the yarn sheet l and exhausts through the exhaust outlet 30.
Dwelling time ~or the yarn in the cooling cabinet 5 is pre-~erably between ~ive and ten seconds. The yarn sheet 1 is cooled after applying the wetting a~ent to the same tempera-ture as the dye in the dye bath 6. In this embodiment the yarn sheet is cooled to about 70 to 75F.
The cooled yarn sheet 1 is then passed o~er a carrier roll 31 and through a set o~ speed control rolls 32 having a movable top roll between two statio~ary guide rolls~
The sheet con$rol rolls 32 control the speed of a motor driving a set of squeeze rolls 33 $hrough which the yarn sheet passesO The squeeze, rolls 33 draw the yarn through the cooling cabinet 5 and -the speed of the rolls may be varied to prevent excessive stretching o~ the yarn sheetO The yarn sheet then passes over a split rod 34 and down into the fîrst of the dye baths 60 Two dye baths 6 are shown, bu* more can be used i~ a deeper shade o~ colour is desiredO Each dye ba$h 6 has upper carrier rolls 35 and lower carrier rolls 36 in the bath 6, and liquid dye 37. The liquid dye 37 covers both the upper and lower carrier rolls 35, 36 in the bath 6 and pre~erably comprises a mixture of water, indigo powder, or the equivalent of indigo paste, in the amount of twenty five grams per litre of waterl eighteen grams per litre of water o~ sodium hydro sulphite, and twenty three grams per litre of caustic soda, The squeeze roll pressure of the squeeze roIls 33 is set to ensure the yarn sheet enters the dye bath 6 at the desired moisture conte~t. The split rod 34 levels out the yarn sheet 1 before it enters the dye bath 6. The yarn sheet 1 is moved through the ~ath 6 passing in zig-zag fashion over the upper and lower carrier rolls 35, 36 and through the liquid dye 37. The yarn sheet 1 pre~erably dwells about 3.3 seconds in the dye.
A~ter leaving bath 6, and before being passed through the second dye bath 6, the yarn sheet 1 is passed through another set oi squeeze rolls 7 followed by a split rod 38 which again levels out the sheet. The squeeze rolls 7 a~e set at a pressure to leave 14-~% liquid dye ln the yarn based on the weight of the yarnO The liquid dye squeezed out from rolls 7 can be retur~ed to bath 6 via a tray 39 beneath rolls 7.
The second dye bath 6 is arranged to retain the sheet 1 within the liquid dye for about 4O4 seconds, the liquid dye 37 in this second bath 6 having the same make-up as the liquid dye in the ~irst bath.
A-fter leaving the second dye bath 6, the yarn shee$
1 is draw~ through the squeeze rolls 7 set at a pressure to leave 14~% liquid dye in the yarn based on the weight of the yarn9 and then enters the oxidizing tank 8 to fix the indigo dye in the yarns. The oxidizi~g tank 8 has a first ~et of upper carrier rolls 40 above the tank and a ~irst set of lower carrier rolls 41 within the tank. Directly above the centre of the oxidizing tank 8 is positioned a set of squeeze rolls 42. A second set o~ upper carrier rolls 44 and a second set of lower carrier rolls 45 are positioned in the second half o~ the tank 8. The tank 8 contains an oxidizing liquor 46 which preferably comprises a solution o~ 0.2% sodium bichromate. The tank 8 is kept at a constant PH with the controlled addition of an acid. In the present system, the PH would be ~ept at a value of 5.5 with the controlled addition of acetic acid. The temperature o~ the bath is main tained constant at around 110F.
The PH in the o~idizing tank is controlled by means o~ a PH analyzer installed ~n the tank. The analy7er is connected to a controller which gives a continuous PH readout on a chart and is connected to a control valve which auto-matically opens and closes allowing acetic acid solution to feed into the tank to keep the PH constant.
Whereas Sodium Bichromate is the pre~erred oxidizing agent, Potassium Iodate, Sodium Iodate, Hydroge~ Peroxide, Sodium Perborate alone or in combination may also be used.
The yarn sheet 1 is passed in zig-zag ~ashion about the ~irst set of upper and lower carrier rolls 40, 41 through tank 8, up through squeeze roll.s 4~, set to apply a pressure o~ l~ tons and down again into tank 8 and about the second set o~ upper and lower carrier rolls 44 9 45 in zig-~,ag ~ashion, and then out o~ the tankO. The yarn sheet l spends about ten seconds i.n the oxidizer tank Bo On leaving the oxidizing tank 8, the yarn sheet 1 is passed through ano$her set o~ squeeze rolls 47 set to apply a pressure o~ 2~ tons. The yarn sheet 1 is now passed through the first of two wash tanks ~ which wash the oxidizer out of -the yarn sheet lo Each wash tank 9 has upper carrier rolls 49 above the tank 9 and lower carrier rolls 50 within the tank 9 and holds hot waterD The water in the ~irst tank 9 is kept at a temperatu~e o~ about 110F, and the water in the second tank 9 is kept at a temperature of about 120F, Fresh water is added to the second tank 9 at the rate of about ten gallons per minute wîth the excess water ~rom the second tank 9 feeding into the ~irst tank 9" The heating means is preferably an open steam coil contro]Lled by a thermostat located in the second tank 9.
The yarn sheet l is drawn in zig-zag ~ashion about the upper and lower carrier rolls 49, 50 and through the water in the tank 9, by a pair v squeeze rolls 51. The squeeze rolls 51 above the second tank 9 are set at a higher pressure than the squeeze rolls 51 above the first tank 9. The squeeze rolls 51 abov~ the first tank 9 are pre~erably set at three tons pressure, and the squeeze rolls 51 above the seco~d tank 9 are pre~erably set at ~our tons pressure.
After washing, the yarn sheet 1 passes over a car-rier roll S2 and is dried in a dry can unit 10 which includes a plurality o~ drying cans 53 arranged in two staggered ver-tical rows. The drying cans 53 are kept hot with steam at 30 P~S~ and the yarn sheet passes backwards and ~orwards 25i~
fr~m can to can in -the two rowsO In this ~'ashion the yarn is dried to a moisture csntent o~ about 12%o The yarn sheet 1 then passes over two Garrier rolls 5~, a split rsd 53 and down into the size bath 11. The yarn sheet, passes over a sub-merged roll 56 in the size bath 11 ~ollowed hy two pairs of squeeze rolls 57 posltioned above the bath llo The size bath contains liquid starch 58 which may include water, 1043 grams per litre of water of modi~ied pearl starch, and 00086 grams per litre of water of sizing compounds. The liquid starch is kep$ at a constant temperature of about 200F by suitable heating means (not shown). The ~irst squeeze rolls 56 are set at a pressure of 8 P.S,I. and the second squeeze rolls 57 at a pressure bf 10 P.S.I. The yarn sheet 1 is passed over the split rod 53 into the size bath 11 under carrier roll 56 and out of the bath throug~ two pairs of squeeze rolls 57. The yarn sheet 1 then passes over a carrier roll 59 into a second dry can unit 12 where the individual drying cans 60 are heated with 60 P.S.I. steam.
This second drying can unit 12 dries the sized yarn sheet 1 to a moisture content of about 7%. Leaving the dry can unit 12 the yarn sheet passes around a carrier roll 6~ and through a plurality of ~plitter rods 63 which separate the yarns 9 and an expansion reed 64 which counts the yarns. The shee-t finally passes through a se-t of carrier rolls 65 be~ore being wound up on the loom beam 13 mounted on creel 660 The preferred speed o~ ~he yarn sheet 1 through the system shown in the present embodiment is 50 yards per minute.
~his speed may be increased by altering the dye formula, increasing the strength o~ the oxidizing liquor~ increasing the wash tank capacity, increasing the dyeing capacity, and including any one or combination of these factors. A yarn speed o~ 50 yards per minute is about twice the speed v~
dyeing yarn in rope ~or7n using the skying method of oxidizing~ .
It wlll be apparent to those skilled in the art that various changes may be mad0 to the embodiment described herein without departing ~rom the scope of the pre~ent invention which is only limited in accordance with the c1aim~, ., ,
This invention relates to an improved process for dyeing yarn with an indigo dye, and a system ~or carrying ou*
the improved processO
Indigo dyes are partioularly suited in the prepara-tion of yarn used for jeans. The indigo dyes fade and faded jeans are in great consumer demandO It is preferred to dye the yarns in yarn form before weaving the yarns into cloth J
and in o~e presently known process of dyeing yarn in a con-tinuous proc0ss rather *han a batch process, multiple ends of yarn i~ sheet form are taken of~ a beam a~d formed in$o a rope, the yarn rope then passes over a series of rollers or pulleys which dip into an indigo dye bath, and then immediately into an air dryi~g or skying step which o~idizes the dye and fixes it in the yarns~ The dipping and skying steps are repeated until the desired shade of colour is obtained in the yarnO The yarn rope is then dried~ and in a separate process called rebeaming, the rope is transformed back into sheet form and rewound on a beam for weaVillg into a fabric used in making jeans This yarn dyeing process is quite slow however, because of the slow oxidizing step required after each immersio~
o~ the yarn rope into a dye bath~ Each skying step can, for e~ample, take up to two minutesO In addi$îon, the ~orma*ion of the yarn into a rope makes it difficult to u~iformly dye the yarns. The yarns in the middle of the rope may end up a lighter shade than the yarns on *he outside of the rope Furthermore, the process of starting with a sheet of yarns, forming a rope for the dyeing s-tep and then reforming a sheet is ine~ficient It is, therefore, a purpose of the present invention to provide an improved continuous process for dyeing yarn with an indigo dye whioh is faster than the known process and which provides a more uniform dyed productO It is also a purpose of the present invention to provide an indigo yarn dyeing process which avoids having to form a sheet of yarns into a rope for the dyeing step 7 and avoids the skying step after dipping in a dye bathO Thus, it is a purpose o~ the present invention to provide an indigo dyeing process which is simpler than the known process.
The present invention provides a process o~ dyeing yarns with indigo dye comprising the steps o~; continuously passing the yarns in sheet form at least once $hrough an indigo dye solution and thereafter squeezing the yarns to remove excess dye solution 9 and passing the dyed yarns through an oxidizing liquor to fix the dye to the yarns.
Preferably the yarn is passed through the system in sheet form rather than rope form thus further speeding up the process since the individual yarns are more accessible for treatment. In addition, the time and apparatus needed to form the yarn sheet into a rope, and from a rope back into sheet form, at the start and finish of dyeing are no$ needed since skying is no lo~ger required. Since the yarns are dyed in sheet form, they can be immediately sized a~ter dyeing and then wound on a loom beam ready ~or weaving thus providing further e-P~icienciesO
The invention is also directed toward a system for dyeing yarns ~ith indigo dye comprising a dye container ~or holding an indigo dye solution, means for passing yarns through the indigo dye solution in the dye container, squeezer -means for remo~ing excess dye solution from the yarns, an o~idizing container ~or holding oxidizing liquor -to fix the dye to the ~arns, means for passing yarns from the squeezer means through the oxidizing liquor in the oxidizing container.
The invention will now be described in detail having , re~erence to the accompanying drawing identi~ied as Figures la, lb and lc which illustrate schematically one embodiment o~ the improved system for indigo dyeing a plurality o~ yarns, The yarns to be,dyed are provided in sheet form 1 wound on beams 2 which can be rotatably supported on creels or stands 3. The yarns are drawn o~f the beams 2 still in sheet ~'orm, and passed through a wash box 4 for applying a heate~ wetting agent to the yarns. The yarns are cooled i~
eooling cabinet 5 and then passed through at least one but pre~erably two or three i ndigo dye baths 6. Aft0r each of the dye baths 6, the yarn sheet 1 is passed through a set of squeeze rolls 7 and a~ter the last squeeze rolls 7, the yarn sheet 1 passes through an oxidizing tank 8 which fixes the indigo dye in the yarns. The yarns are then washed in one or two wash tanks 9 and dried over drying cans 10. The yarn sheet 1 is then si~ed in a size bath 11 and dried over a second set o~ drying cans 12, The yarn sheet 1 is then wound on a loom beam 13 with the dyed yarns ready ~or weaving.
In more detail, a pair o~ ~irivell rolls 20, pull the sheet 1 from the beams 2, when~e it is passed under two carrier rolls 21 submer~ed in the wash box 4. In the embodi-ment shown multiple creels are used, each creel having 400 ends o-~ yarn. With twelve creels this gives a sheet havi~g 4800 ends o~ yarn. A pair of squeeze rolls 22 are mounted above the wash box 4 to squeeze excess liquid out of the yarn sheet 1 and return it t o the wa~h box 4. The wash box 4 holds a wetting agent liquid 23 which treats the yarn to allow it to more easily pick up dye, The wetting agent liquid 23 pr0~erably cvmprises a mi~ture o~ water, a wetting agent such as that known under the trade mark Levapon A,N., and caustic soda, pre~erably in the proportions o~ 65 gallo~s water, 2028 grams per litre o~ Levapon A,N., and 5047 grams per litre of caustic soda. The wet-ting agent liquid 23 pre~rably i~ maintained at a temperature o~ about 200F
by suitable heating means such as a clssed steam coll, (not shown). The squeeze rolls 22 are set at a pressure to leave about 50% liquid in the yarns based on the weight of the yarn~
After leaving the squeeze rolls 22, the yarn sheet l is passed over a carrier roll 24 and then enters the en-closed cabinet 5 which comprises upper carrier rolls 25 and lower carrier rolls 26 within the cabinet, an inlet 27 for the sheet at o~e side o~ the cabinet, an outlet 28 for the sheet at the other side o~ the cabinet, air inlets 29 in the body of -the cabinet 5 and an exhaust air outlet 30 at the top of the cabinet. The exhaust air outlet 30 has an exhaust ~an (not shown) to cause a circulation o~ air through the cabinet 5. The yarn sheet l passes through inlet 27 into cabinet 5. In the diagram the sheet is shown threaded between the first upper and first lower carriQr rolls 25, 26 within the cabinet 5 and then is passed over only the upper rolls 25, finishing o~ on the last lower and upper roll 26, 25 before exitîng fro~ outlet 28. In t'he embodiment shown, the majority of lower rolls 26 are not used, however, i~ greater cooling is required or higher sheet speeds are used, then the sheet may pass back and forwards ~rom upper to lower rolls.
Air passes through the inlets 29 in the cabinet 5 to cool the yarn sheet l and exhausts through the exhaust outlet 30.
Dwelling time ~or the yarn in the cooling cabinet 5 is pre-~erably between ~ive and ten seconds. The yarn sheet 1 is cooled after applying the wetting a~ent to the same tempera-ture as the dye in the dye bath 6. In this embodiment the yarn sheet is cooled to about 70 to 75F.
The cooled yarn sheet 1 is then passed o~er a carrier roll 31 and through a set o~ speed control rolls 32 having a movable top roll between two statio~ary guide rolls~
The sheet con$rol rolls 32 control the speed of a motor driving a set of squeeze rolls 33 $hrough which the yarn sheet passesO The squeeze, rolls 33 draw the yarn through the cooling cabinet 5 and -the speed of the rolls may be varied to prevent excessive stretching o~ the yarn sheetO The yarn sheet then passes over a split rod 34 and down into the fîrst of the dye baths 60 Two dye baths 6 are shown, bu* more can be used i~ a deeper shade o~ colour is desiredO Each dye ba$h 6 has upper carrier rolls 35 and lower carrier rolls 36 in the bath 6, and liquid dye 37. The liquid dye 37 covers both the upper and lower carrier rolls 35, 36 in the bath 6 and pre~erably comprises a mixture of water, indigo powder, or the equivalent of indigo paste, in the amount of twenty five grams per litre of waterl eighteen grams per litre of water o~ sodium hydro sulphite, and twenty three grams per litre of caustic soda, The squeeze roll pressure of the squeeze roIls 33 is set to ensure the yarn sheet enters the dye bath 6 at the desired moisture conte~t. The split rod 34 levels out the yarn sheet 1 before it enters the dye bath 6. The yarn sheet 1 is moved through the ~ath 6 passing in zig-zag fashion over the upper and lower carrier rolls 35, 36 and through the liquid dye 37. The yarn sheet 1 pre~erably dwells about 3.3 seconds in the dye.
A~ter leaving bath 6, and before being passed through the second dye bath 6, the yarn sheet 1 is passed through another set oi squeeze rolls 7 followed by a split rod 38 which again levels out the sheet. The squeeze rolls 7 a~e set at a pressure to leave 14-~% liquid dye ln the yarn based on the weight of the yarnO The liquid dye squeezed out from rolls 7 can be retur~ed to bath 6 via a tray 39 beneath rolls 7.
The second dye bath 6 is arranged to retain the sheet 1 within the liquid dye for about 4O4 seconds, the liquid dye 37 in this second bath 6 having the same make-up as the liquid dye in the ~irst bath.
A-fter leaving the second dye bath 6, the yarn shee$
1 is draw~ through the squeeze rolls 7 set at a pressure to leave 14~% liquid dye in the yarn based on the weight of the yarn9 and then enters the oxidizing tank 8 to fix the indigo dye in the yarns. The oxidizi~g tank 8 has a first ~et of upper carrier rolls 40 above the tank and a ~irst set of lower carrier rolls 41 within the tank. Directly above the centre of the oxidizing tank 8 is positioned a set of squeeze rolls 42. A second set o~ upper carrier rolls 44 and a second set of lower carrier rolls 45 are positioned in the second half o~ the tank 8. The tank 8 contains an oxidizing liquor 46 which preferably comprises a solution o~ 0.2% sodium bichromate. The tank 8 is kept at a constant PH with the controlled addition of an acid. In the present system, the PH would be ~ept at a value of 5.5 with the controlled addition of acetic acid. The temperature o~ the bath is main tained constant at around 110F.
The PH in the o~idizing tank is controlled by means o~ a PH analyzer installed ~n the tank. The analy7er is connected to a controller which gives a continuous PH readout on a chart and is connected to a control valve which auto-matically opens and closes allowing acetic acid solution to feed into the tank to keep the PH constant.
Whereas Sodium Bichromate is the pre~erred oxidizing agent, Potassium Iodate, Sodium Iodate, Hydroge~ Peroxide, Sodium Perborate alone or in combination may also be used.
The yarn sheet 1 is passed in zig-zag ~ashion about the ~irst set of upper and lower carrier rolls 40, 41 through tank 8, up through squeeze roll.s 4~, set to apply a pressure o~ l~ tons and down again into tank 8 and about the second set o~ upper and lower carrier rolls 44 9 45 in zig-~,ag ~ashion, and then out o~ the tankO. The yarn sheet l spends about ten seconds i.n the oxidizer tank Bo On leaving the oxidizing tank 8, the yarn sheet 1 is passed through ano$her set o~ squeeze rolls 47 set to apply a pressure o~ 2~ tons. The yarn sheet 1 is now passed through the first of two wash tanks ~ which wash the oxidizer out of -the yarn sheet lo Each wash tank 9 has upper carrier rolls 49 above the tank 9 and lower carrier rolls 50 within the tank 9 and holds hot waterD The water in the ~irst tank 9 is kept at a temperatu~e o~ about 110F, and the water in the second tank 9 is kept at a temperature of about 120F, Fresh water is added to the second tank 9 at the rate of about ten gallons per minute wîth the excess water ~rom the second tank 9 feeding into the ~irst tank 9" The heating means is preferably an open steam coil contro]Lled by a thermostat located in the second tank 9.
The yarn sheet l is drawn in zig-zag ~ashion about the upper and lower carrier rolls 49, 50 and through the water in the tank 9, by a pair v squeeze rolls 51. The squeeze rolls 51 above the second tank 9 are set at a higher pressure than the squeeze rolls 51 above the first tank 9. The squeeze rolls 51 abov~ the first tank 9 are pre~erably set at three tons pressure, and the squeeze rolls 51 above the seco~d tank 9 are pre~erably set at ~our tons pressure.
After washing, the yarn sheet 1 passes over a car-rier roll S2 and is dried in a dry can unit 10 which includes a plurality o~ drying cans 53 arranged in two staggered ver-tical rows. The drying cans 53 are kept hot with steam at 30 P~S~ and the yarn sheet passes backwards and ~orwards 25i~
fr~m can to can in -the two rowsO In this ~'ashion the yarn is dried to a moisture csntent o~ about 12%o The yarn sheet 1 then passes over two Garrier rolls 5~, a split rsd 53 and down into the size bath 11. The yarn sheet, passes over a sub-merged roll 56 in the size bath 11 ~ollowed hy two pairs of squeeze rolls 57 posltioned above the bath llo The size bath contains liquid starch 58 which may include water, 1043 grams per litre of water of modi~ied pearl starch, and 00086 grams per litre of water of sizing compounds. The liquid starch is kep$ at a constant temperature of about 200F by suitable heating means (not shown). The ~irst squeeze rolls 56 are set at a pressure of 8 P.S,I. and the second squeeze rolls 57 at a pressure bf 10 P.S.I. The yarn sheet 1 is passed over the split rod 53 into the size bath 11 under carrier roll 56 and out of the bath throug~ two pairs of squeeze rolls 57. The yarn sheet 1 then passes over a carrier roll 59 into a second dry can unit 12 where the individual drying cans 60 are heated with 60 P.S.I. steam.
This second drying can unit 12 dries the sized yarn sheet 1 to a moisture content of about 7%. Leaving the dry can unit 12 the yarn sheet passes around a carrier roll 6~ and through a plurality of ~plitter rods 63 which separate the yarns 9 and an expansion reed 64 which counts the yarns. The shee-t finally passes through a se-t of carrier rolls 65 be~ore being wound up on the loom beam 13 mounted on creel 660 The preferred speed o~ ~he yarn sheet 1 through the system shown in the present embodiment is 50 yards per minute.
~his speed may be increased by altering the dye formula, increasing the strength o~ the oxidizing liquor~ increasing the wash tank capacity, increasing the dyeing capacity, and including any one or combination of these factors. A yarn speed o~ 50 yards per minute is about twice the speed v~
dyeing yarn in rope ~or7n using the skying method of oxidizing~ .
It wlll be apparent to those skilled in the art that various changes may be mad0 to the embodiment described herein without departing ~rom the scope of the pre~ent invention which is only limited in accordance with the c1aim~, ., ,
Claims (18)
1. A process of dyeing yarns with indigo dye comprising the steps of:
continuously passing the yarns in sheet form at least once through an indigo dye solution and thereafter squeezing the yarns to remove excess dye solution, and passing the dyed yarns through an oxidizing liquor to fix the dye to the yarns.
continuously passing the yarns in sheet form at least once through an indigo dye solution and thereafter squeezing the yarns to remove excess dye solution, and passing the dyed yarns through an oxidizing liquor to fix the dye to the yarns.
2. The process according to claim 1 wherein the yarns are passed in sheet form through an indigo dye solution on rollers in a dye tank followed by squeeze rolls adjacent the dye tank, and wherein the dyed yarns are passed through the oxidizing liquor on rollers in a tank followed by squeeze rolls adjacent the tank.
3. The process according to claim 2 wherein the yarns are passed through at least two dye tanks each followed by squeeze rolls.
4. The process according to any of claims 1, 2 or 3 wherein the yarns pass through the oxidizing liquor at least twice, and are squeezed in between.
5. The process according to any of claims 1, 2 or 3 including maintaining the oxidizing liquor at a constant PH.
6. The process according to any of claims 1, 2 or 3 wherein the oxidizing liquor contains at least 0.2%
sodium bichromate.
sodium bichromate.
7. The process according to any of claims 1, 2 or 3 wherein the oxidizing liquor contains an oxidizing agent selected from the group consisting of, Sodium Bichromate, Potassium Iodate, Sodium Iodate, Hydrogen Peroxide, Sodium Perborate, alone or in combinations thereof.
8. The process according to any of claims 1, 2 or 3 wherein the oxidizing liquor contains at least 0.2%
Sodium Bichromate and including maintaining the oxidizing liquor at a constant PH of approximately 5.5 with acetic acid.
Sodium Bichromate and including maintaining the oxidizing liquor at a constant PH of approximately 5.5 with acetic acid.
9. The process according to any of claims 1, 2 or 3 wherein the yarns in sheet form are continuously passed at an approximate speed of 50 yards per minute.
10. A system for dyeing yarns with indigo dye comprising, a dye container for holding an indigo dye solution, means for passing yarns through the indigo dye solution in the container, squeezer means for removing excess dye solution from the yarns, an oxidizing container for holding oxidizing liquor to fix the dye to the yarns, means for passing yarns from the squeezer means through the oxidizing liquor in the oxidizing container.
11, The system according to claim 10 wherein the dye and containers are tanks, the means to pass the yarns through the dye and oxidizing containers are rollers and the squeezer means are a pair of squeeze rolls, including a further pair of squeeze rolls positioned to squeeze the yarns exiting from the oxidizing tank.
12. The system according to claim 10 including at least two dye containers, each container having squeezer means to squeeze the yarns exiting from each container.
13. The system according to any of claims 10, 11 or 12 wherein the means to pass the yarns through the dye and oxidizing containers include means for passing yarns in sheet form.
14. The system according to any of claims 10, 11 or 12 wherein the oxidizing container is divided into two sections and the means for passing the yarns through the oxidizing container is also in two sections with a pair of squeeze rolls after each section.
15. The system according to any of claims 10, 11 or 12 including means for maintaining the PH of the oxidizing liquor in the oxidizing containers.
16. The system according to any of claims 10, 11 or 12 including means for applying a wetting agent to the yarns before passing through the dye container.
17. The system according to any of claims 10, 11 or 12 including sizing means for sizing the yarns after passing through the oxidizing container.
18. The system according to any of claims 10, 11 or 12 wherein the yarns are passed through the dye and oxidizing containers in sheet form and at a speed of approxi-mately 50 yards per minute.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA297,106A CA1098258A (en) | 1978-02-14 | 1978-02-14 | Indigo dyeing process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA297,106A CA1098258A (en) | 1978-02-14 | 1978-02-14 | Indigo dyeing process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1098258A true CA1098258A (en) | 1981-03-31 |
Family
ID=4110789
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA297,106A Expired CA1098258A (en) | 1978-02-14 | 1978-02-14 | Indigo dyeing process |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1098258A (en) |
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4756037A (en) * | 1986-04-23 | 1988-07-12 | Cotton Incorporated | Continuous garment dyeing with indigo and other vat dyes |
| US4845789A (en) * | 1986-04-23 | 1989-07-11 | Cotton Incorporated | Dyeing of garments with low-substantivity vat dyes |
| EP0408269A2 (en) * | 1989-07-10 | 1991-01-16 | MITSUI TOATSU CHEMICALS, Inc. | Rope dyeing process using indigo derivative and dyed article thus obtained |
| US5375281A (en) * | 1992-01-29 | 1994-12-27 | Hans-Jorg Hamann | Method for treating and in particular dyeing fabric warp-threads |
| US5935273A (en) * | 1997-02-08 | 1999-08-10 | Kruger; Rudolf | Process for continuous dyeing of cellulose-containing yarn with indigo in a single application while controlling the pH value |
| US6123741A (en) * | 1998-02-26 | 2000-09-26 | Girbaud; Francois | Process for dyeing a textile material with indigo and arrangement for conducting the process |
| WO2006013458A1 (en) * | 2004-07-29 | 2006-02-09 | Master S.A.S. Di Ronchi Francesco & C. | Dyeing device and processes using indigo and other colorants |
| DE102015218510A1 (en) | 2015-09-25 | 2017-03-30 | Cht R. Beitlich Gmbh | Textile fabrics with denim-like features |
| WO2020101592A1 (en) * | 2018-11-16 | 2020-05-22 | Denge Ki̇mya Ve Teksti̇l Sanayi̇ Ti̇caret Anoni̇m Şi̇rketi̇ | Closed system indigo fent dyeing method |
-
1978
- 1978-02-14 CA CA297,106A patent/CA1098258A/en not_active Expired
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4756037A (en) * | 1986-04-23 | 1988-07-12 | Cotton Incorporated | Continuous garment dyeing with indigo and other vat dyes |
| US4845789A (en) * | 1986-04-23 | 1989-07-11 | Cotton Incorporated | Dyeing of garments with low-substantivity vat dyes |
| EP0408269A2 (en) * | 1989-07-10 | 1991-01-16 | MITSUI TOATSU CHEMICALS, Inc. | Rope dyeing process using indigo derivative and dyed article thus obtained |
| EP0408269A3 (en) * | 1989-07-10 | 1991-12-04 | Mitsui Toatsu Chemicals, Incorporated | Rope dyeing process using indigo derivative and dyed article thus obtained |
| US5375281A (en) * | 1992-01-29 | 1994-12-27 | Hans-Jorg Hamann | Method for treating and in particular dyeing fabric warp-threads |
| US5935273A (en) * | 1997-02-08 | 1999-08-10 | Kruger; Rudolf | Process for continuous dyeing of cellulose-containing yarn with indigo in a single application while controlling the pH value |
| US6123741A (en) * | 1998-02-26 | 2000-09-26 | Girbaud; Francois | Process for dyeing a textile material with indigo and arrangement for conducting the process |
| WO2006013458A1 (en) * | 2004-07-29 | 2006-02-09 | Master S.A.S. Di Ronchi Francesco & C. | Dyeing device and processes using indigo and other colorants |
| US8060963B2 (en) | 2004-07-29 | 2011-11-22 | Master S.A.S. Di Ronchi Francesco & C. | Dyeing device and process using indigo and other colorants |
| DE102015218510A1 (en) | 2015-09-25 | 2017-03-30 | Cht R. Beitlich Gmbh | Textile fabrics with denim-like features |
| WO2017050646A1 (en) | 2015-09-25 | 2017-03-30 | Cht R. Beitlich Gmbh | Textile fabrics with denim-like features |
| WO2020101592A1 (en) * | 2018-11-16 | 2020-05-22 | Denge Ki̇mya Ve Teksti̇l Sanayi̇ Ti̇caret Anoni̇m Şi̇rketi̇ | Closed system indigo fent dyeing method |
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