Fabric hydroenhancement method & equipment for improved efficiency

Abstract

Improvements in hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. For example, a low energy per pass of 1/10 to 1/48 the total energy delivered in 10 passes or more can obtain good enhancement results as compared to conventional hydroenhancing at higher total energy levels delivered in fewer passes. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy-per-pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. In one embodiment, a jigging hydroenhancing equipment transports the fabric back and forth under a stationary manifold between a pair of unwind/windup reels to simulate multiple passes on the fabric. Other embodiments employ a manifold or manifold system that is reciprocated, oscillated, or rotated to simulate multiple passes on the fabric. Other variations for improving hydroenhancement include angling the manifold at a diagonal to the fabric travel direction, using a high density number or double rows of jets to eliminate interference patterns, using combined upstream and downstream manifolds together for improved coverage on the fabric, and providing a baffle in the manifold in proximity to the jet strip to generate constantly fluctuating jets for improved utilization of enhancement energy.

We claim:  
     
         1 . An improved hydroenhancing equipment, comprising: 
 a manifold having a row of jet orifices which emit a curtain of fluid jets at a given level of total delivered energy per weight of fabric;    transport means for transporting the fabric in a travel direction at a given speed relative to the manifold so that the curtain of fluid jets impacts on the fabric;    wherein the manifold is operated in movement relative to the transporting of the fabric such that the curtain of fluid jets is delivered to the fabric at a low energy per pass which is a selected fraction of the given level of total delivered energy and in a high number of passes on the fabric which is a multiple corresponding to the selected fraction, whereby an improved conversion of delivered energy to enhancement energy is obtained on each pass and waste of energy is reduced.    
     
     
         2 . An improved hydroenhancing equipment according to  claim 1 , wherein the manifold is stationary and a pair of unwind/windup reels are provided as said transport means for jigging the fabric back and forth a number of times under the manifold to simulate multiple passes on the fabric.  
     
     
         3 . An improved hydroenhancing equipment according to  claim 2 , wherein another stationary manifold is arranged on an opposite side of the fabric, so that both sides of the fabric are treated in one process run.  
     
     
         4 . An improved hydroenhancing equipment according to  claim 2 , wherein a small-diameter support roll is arranged to support the fabric on a side opposite from the manifold and is aligned relative to the manifold at an angle to the vertical direction so as to allow for drainage of fluid downward away from the path of the fabric around the support roll.  
     
     
         5 . An improved hydroenhancing equipment according to  claim 4 , wherein water drainage means is provided for the drainage of fluid downward away from the path of the fabric and forms part of a compact containment structure containing the manifold and support roll.  
     
     
         6 . An improved hydroenhancing equipment according to  claim 2 , wherein said transport means jigs the fabric back and forth in a range of from 9 to 23 times, depending on fabric weight, line speed and fluid pressure.  
     
     
         7 . An improved hydroenhancing equipment according to  claim 1 , wherein the manifold is reciprocated back and forth a number of times in a cross direction relative to the travel direction of the transported fabric to simulate multiple passes per given area of the fabric.  
     
     
         8 . An improved hydroenhancing equipment according to  claim 7 , wherein the manifold is formed as a short, compact section having a width less than the width of the fabric and is reciprocated across the travel direction of the fabric to apply the fluid jets in overlapping swathes on the fabric.  
     
     
         9 . An improved hydroenhancing equipment according to  claim 8 , wherein the fabric has a given width and is transported at a given line speed, and the manifold has a jet curtain width of one-third the fabric width and is reciprocated in the cross direction at a speed of about 48 times the line speed in order to simulate 16 passes per given area of the fabric.  
     
     
         10 . An improved hydroenhancing equipment according to  claim 8 , wherein the short section of manifold is reciprocated at a diagonal angle to the fabric travel direction for eliminating the generation of interference patterns in the fabric.  
     
     
         11 . An improved hydroenhancing equipment according to  claim 1 , wherein two manifolds are spaced apart in parallel extending across the width of the fabric and are coupled together by a spring element and oscillated in opposite phase to each other to simulate multiple passes on the fabric while conserving oscillation energy.  
     
     
         12 . An improved hydroenhancing equipment according to  claim 11 , wherein the two manifolds are arranged on the same side of the fabric to double the number of passes with each oscillation.  
     
     
         13 . An improved hydroenhancing equipment according to  claim 12 , wherein the two manifolds are oscillated at 6 Hertz with an oscillation amplitude of 2.4″ to provide the equivalent of 24 passes over fabric moving at a line speed of 10 fpm.  
     
     
         14 . An improved hydroenhancing equipment according to  claim 11 , wherein the two manifolds are arranged on opposite sides of the fabric to treat both sides of the fabric in one process run.  
     
     
         15 . An improved hydroenhancing equipment according to  claim 11 , wherein the two manifolds are angled across the fabric travel direction and oscillate on a diagonal for eliminating the generation of interference patterns in the fabric.  
     
     
         16 . An improved hydroenhancing equipment according to  claim 1 , wherein the manifold is a drum manifold having a plurality of jet strips with respective rows of jet orifices mounted around the periphery thereof, said drum manifold being rotated to apply the fluid curtains from the plurality of jet strips in overlapping swathes to simulate multiple passes on the fabric.  
     
     
         17 . An improved hydroenhancing equipment according to  claim 16 , wherein the drum manifold is arranged at a diagonal angle to the fabric travel direction to eliminate the generation of interference patterns in the fabric.  
     
     
         18 . An improved hydroenhancing equipment according to  claim 16 , wherein the drum manifold has three jet strips mounted thereon and is rotated to have a surface velocity in the fabric travel direction at four times the speed of fabric transport so as to simulate nine passes over the fabric in a process run.  
     
     
         19 . An improved hydroenhancing equipment according to  claim 16 , wherein the drum manifold has three jet strips mounted thereon and is rotated to have a surface velocity opposite to the fabric travel direction at four times the speed of fabric transport so as to simulate 15 passes over the fabric in a process run.  
     
     
         20 . An improved hydroenhancing equipment according to  claim 1 , wherein two manifolds are spaced apart in parallel on opposite sides of the fabric and are coupled together by a spring element and oscillated in opposite phase to each other, in order to simulate multiple passes on both sides of the fabric in a process run while conserving oscillation energy.  
     
     
         21 . An improved hydroenhancing equipment according to  claim 20 , wherein means are provided in conjunction with said unwind and windup reels for dispensing and accumulating the fabric in incremental advances under the manifolds as the fabric is supplied from and wound on reels continuously.  
     
     
         22 . An improved manifold for hydroenhancing fabric, comprising: 
 a manifold body having a main plenum in a central portion thereof and at least one cavity formed in a peripheral portion thereof and extending in an axial direction of the manifold body for removably mounting a flow module assembly therein;    a flow module having an upper wall defining an inlet for receiving high pressure fluid from said main plenum of said manifold body, a lower wall having means for holding a jet strip having a row of jet orifices for emitting fluid jets from the manifold, and module walls defining an interior plenum therein for distributing a flow of the high pressure fluid received through the inlet to the orifices of the jet strip;    wherein said manifold body cavity has cavity walls of a shape corresponding to the external shape of the flow module walls so as to allow insertion of the flow module into said cavity along the axial direction with a clearance space therebetween; and    a pair of rigid, elongated sealing strips which are forcibly inserted in the axial direction between the cavity walls of the manifold body and the walls of the inserted flow module on opposite sides of the lower wall of the flow module holding said jet strip therein, for holding said flow module tightly in said cavity and sealing the cavity.    
     
     
         23 . An improved manifold according to  claim 22 , wherein said flow module includes a baffle positioned in close proximity to the jet strip for creating turbulence in the fluid flow to the jet strip such that the jets emitted from the jet orifices have a constantly fluctuating cross-sectional shape and direction.  
     
     
         24 . An improved manifold according to  claim 23 , wherein said baffle is a metal plate bent to form a rigid channel shape with a central constriction for the flow of fluid from the inlet to the jet orifices.  
     
     
         25 . An improved manifold according to  claim 22 , wherein said flow module has a elongated circular groove formed in a top surface of its upper wall around said inlet to said flow module, and an O-ring is fitted into said groove for sealing the top surface of the flow module and the cavity.  
     
     
         26 . An improved manifold according to  claim 22 , wherein the cavity walls and the walls of the flow module are corresponding angled for seating of the flow module in the cavity and sealing the flow module against the cavity walls.  
     
     
         27 . An improved manifold according to  claim 22 , wherein said manifold body is formed as a drum having a plurality of cavities on its periphery for removably mounting a corresponding plurality of flow module assemblies and respective jet strips therein.  
     
     
         28 . An improved manifold according to  claim 27 , wherein said drum manifold is rotated at a predetermined speed so as to simulate multiple passes of the jet streams of the plurality of jet strips on a fabric.  
     
     
         29 . An improved hydroenhancing equipment, comprising: 
 a combination manifold having combined rows of jet orifices for emitting respective curtains of fluid jets to impact on a fabric;    a transport surface for transporting the fabric in a given travel direction relative to the manifold;    wherein the combination manifold includes a downstream manifold relative to the fabric travel direction for emitting fluid jets pointing straight downward on the fabric, and an upstream manifold relative to the fabric travel direction for emitting jets canted at an angle toward the fabric travel direction to impact toward the impact zone of the downstream manifold for greater blooming of yarns in the impact zone of the fabric.    
     
     
         30 . An improved hydroenhancing equipment according to  claim 29 , wherein the upstream manifold is provided with orifices having a dense spacing of jets greater than a spacing of yarns in the fabric to eliminate interference patterns.  
     
     
         31 . An improved hydroenhancing equipment according to  claim 30 , wherein the upstream manifold is provided with orifices arranged in a double row of 60 jets/inch, the upstream manifold is canted at a 45° angle toward the fabric travel direction, and has an impact on the fabric equivalent to a jet density of 168 jets/inch.  
     
     
         32 . An improved method of hydroenhancing fabric using a manifold having a row of jet orifices which emit a curtain of fluid jets at a given level of total delivered energy per weight of fabric to impact on a side of the fabric as it is transported in a travel direction at a given speed relative to the manifold, wherein the improvement comprises operating the manifold in movement relative to the transporting of the fabric such that the curtain of fluid jets delivers a low energy to the fabric per pass which is a selected fraction of the given level of total delivered energy and in a high number of passes over the fabric which is a multiple corresponding to the selected fraction, whereby an improved conversion of delivered energy to enhancement energy is obtained on each pass and waste of energy is reduced.  
     
     
         33 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold comprises at least one stationary manifold extending across the width of the fabric, and the fabric is transported under the manifold at a high speed such that the total delivered energy to the fabric per manifold is 0.0625 hp-hr/lb or lower.  
     
     
         34 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the energy delivered to the fabric per pass is in the range of about {fraction (1/10)} to {fraction (1/48)} of the total delivered energy, and the number of passes on the fabric is 10 or higher.  
     
     
         35 . An improved method of hydroenhancing fabric according to  claim 32 , wherein a fabric made of polyester spun yarn is treated with a total delivered energy of 0.25 hp-hr/lb or lower in 16 passes or higher and has a fabric coverage (measured in terms of air permeability) in the range of about 60 cfm/ft2 or lower.  
     
     
         36 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is reciprocated back and forth in a cross direction relative to the transport direction of the fabric to simulate multiple passes on the fabric in a process run.  
     
     
         37 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is reciprocated at a diagonal angle to the fabric travel direction to eliminate the generation of interference patterns in the fabric.  
     
     
         38 . An improved method of hydroenhancing fabric according to  claim 32 , wherein two manifolds are spaced apart in parallel extending across the width of the fabric and are oscillated in opposite phase to each other to simulate multiple passes on the fabric.  
     
     
         39 . An improved method of hydroenhancing fabric according to  claim 38 , wherein the two manifolds are arranged on the same side of the fabric to double the number of passes with each oscillation.  
     
     
         40 . An improved method of hydroenhancing fabric according to  claim 38 , wherein the two manifolds are arranged on opposite sides of the fabric to treat both sides of the fabric in one process run.  
     
     
         41 . An improved method of hydroenhancing fabric according to  claim 38 , wherein the two manifolds are oscillated at a diagonal angle to the fabric travel direction to eliminate the generation of interference patterns in the fabric.  
     
     
         42 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is a drum manifold having a plurality of jet strips mounted thereto and is rotated to apply jet curtains in overlapping swathes to simulate multiple passes on the fabric.  
     
     
         43 . An improved method of hydroenhancing fabric according to  claim 42 , wherein the drum manifold is arranged at a diagonal angle to the fabric travel direction to eliminate the generation of interference patterns in the fabric.  
     
     
         44 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is stationary and the fabric is transported back and forth under the manifold a number of times between a pair of unwind/windup reels to simulate multiple passes on the fabric.  
     
     
         45 . An improved method of hydroenhancing fabric according to  claim 44 , wherein two stationary manifolds are arranged on opposite sides of the fabric to treat both sides of the fabric in a process run.  
     
     
         46 . An improved method of hydroenhancing fabric according to  claim 32 , wherein two manifolds are arranged on opposite sides of the fabric and are coupled together and oscillated to simulate multiple passes on both sides of the fabric in a process run.  
     
     
         47 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is provided with a high jet density of from 100 to 200 jets/inch in the row of jet orifices for treating woven fabric having a yarn density of 40 warp-yarns/inch or more in order to eliminate the generation of interference patterns in the fabric.  
     
     
         48 . An improved method of hydroenhancing fabric according to  claim 47 , wherein the high jet density is provided by arranging the jet orifices in two rows offset from and in close proximity to each other.  
     
     
         49 . An improved method of hydroenhancing fabric according to  claim 32 , wherein the manifold is provided with jet orifices which emit fans jets forming a continuous water curtain on the fabric in order to eliminate the generation of interference patterns in the fabric.