Compactor for lengthwise compressive shrinkage of fabrics

Abstract

A compactor for lengthwise compressive shrinkage of fabrics including an infeed roller and an outfeed roller that are fixed positioned parallel to one another as to define a compaction zone, a pressure roller that is movable and positioned above the compaction zone as to be self-centering between the infeed roller and the outfeed roller and as to define an infeed nip-point between the infeed roller and the pressure roller and an outfeed nip-point between the outfeed roller and the pressure roller, and a saddle assembly positioned within the compaction zone, the saddle assembly including a bed liner having an upper surface facing the pressure roller and a lower surface opposite the upper surface.

What is claimed is: 
     
         1 . A compactor for lengthwise compressive shrinkage of fabrics, comprising:
 an infeed roller rotating about an infeed center axis that is fixed and having an infeed outer surface;   an outfeed roller rotating about an outfeed center axis that is fixed and having an outfeed outer surface;   the infeed center axis and the outfeed center axis positioned parallel to one another as to define a compaction zone between the infeed roller and the outfeed roller, the compaction zone having a first longitudinal length and a first transversal width;   a pressure roller rotating about a pressure center axis that is movable and having a pressure outer surface;   the pressure center axis movable above the compaction zone as to be self-centering between the infeed roller and the outfeed roller and as to define an infeed nip-point between the infeed roller and the pressure roller and an outfeed nip-point between the outfeed roller and the pressure roller; and   a saddle assembly positioned within the compaction zone, the saddle assembly including a bed liner having an upper surface facing the pressure roller and a lower surface opposite the upper surface;   the upper surface having a second longitudinal length that traverses a portion of the first longitudinal length and having a second transversal width that traverses a portion of the first transversal width.   
     
     
         2 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the bed liner is comprised of a flexible material so as to bias a fabric positioned on the upper surface of the bed liner against the pressure outer surface. 
     
     
         3 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 2 , wherein the bed liner further includes a plurality of holes running along the first longitudinal length of the upper surface. 
     
     
         4 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the bed liner is comprised of a rigid material so as to bias a fabric positioned on the upper surface against the pressure outer surface. 
     
     
         5 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 4 , wherein the bed liner includes a pair of embedded channels running along the first longitudinal length of the upper surface; and
 a plurality of holes positioned above each of the pair of embedded channels.   
     
     
         6 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the second transversal width of the upper surface is equal to the first transversal width of the compaction zone. 
     
     
         7 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 6 , wherein the lower surface of the bed liner at opposing transversal ends of the bed liner rest on the infeed outer surface and the outfeed outer surface. 
     
     
         8 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 7 , wherein the transversal ends of the bed liner are machined either straight, chamfered, or smooth. 
     
     
         9 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein a diameter of the pressure roller is at least greater than the first transversal width of the compaction zone. 
     
     
         10 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , further comprising
 a first variable-speed drive rotating the infeed roller as to provide the infeed outer surface with a first surface speed;   a second variable-speed drive rotating the outfeed roller as to provide the outfeed outer surface with a second surface speed; and   a third variable-speed drive rotating the pressure roller as to provide the pressure outer surface with a third surface speed.   
     
     
         11 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 10 , wherein the second surface speed of the outfeed outer surface is less than the first surface speed of the infeed outer surface. 
     
     
         12 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 10 , wherein the third surface speed of the pressure outer surface is equal to the first surface speed of the infeed outer surface. 
     
     
         13 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , further comprising a saddle coupled to the bed liner so as to support the bed liner within the compaction zone. 
     
     
         14 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 13 , further comprising a rib coupled to the lower surface of the bed liner; and
 wherein the saddle includes an insert in which the rib is received.   
     
     
         15 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the pressure center axis moves to define an infeed gap at the infeed nip-point and an outfeed gap at the outfeed nip-point, the infeed gap and the outfeed gap each determined by a thickness of a fabric driven through the compaction zone by the infeed roller and the outfeed roller. 
     
     
         16 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 15 , wherein the infeed roller and the pressure roller are both heated to at least a nominal temperature that is sufficient to prevent heat transfer from a preheated fabric while in contact with the infeed roller and the pressure roller. 
     
     
         17 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the infeed roller and the pressure roller are heated. 
     
     
         18 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein the infeed roller, the outfeed roller, and the pressure roller each rotate in a direction to drive a heated fabric from the infeed nip-point, across the compaction zone, and towards the outfeed nip-point. 
     
     
         19 . The compactor for lengthwise compressive shrinkage of fabrics of  claim 1 , wherein
 the infeed outer surface having a first traction coefficient;   the outfeed outer surface having a second traction coefficient; and the   the pressure outer surface having a third traction coefficient.   
     
     
         20 . A method for lengthwise compressive shrinkage of fabrics, comprising:
 providing an infeed roller rotating about an infeed center axis that is fixed and having an infeed outer surface;   providing an outfeed roller rotating about an outfeed center axis that is fixed and having an outfeed outer surface;   positioning the infeed roller and the outfeed roller parallel to one another as to define a compaction zone between the infeed roller and the outfeed roller, the compaction zone having a first longitudinal length and a first transversal width;   providing a pressure roller rotating about a pressure center axis that is movable and having a pressure outer surface;   moving the pressure center axis above the compaction zone as to be self-centering between the infeed roller and the outfeed roller and as to define an infeed nip-point between the infeed roller and the pressure roller and an outfeed nip-point between the outfeed roller and the pressure roller; and   providing a saddle assembly positioned within the compaction zone, the saddle assembly including a bed liner having an upper surface facing the pressure roller and a lower surface opposite the upper surface;   the upper surface having a second longitudinal length that traverses a portion of the first longitudinal length and having a second transversal width that traverses a portion of the first transversal width.