Device for intensifying the interchange between a liquid and a textile material immersed in a tank containing this liquid

Abstract

A device (10) for intensifying the interchange between a liquid (W) and a textile material (T) is disclosed. The intensifier device (10) consists of a body having cylindrical geometry which comprises a central rod-shaped support structure (12), which extends along an axial direction (A), a pair of opposite end plates (14), which are integrally mounted on the central support structure (12) at respective terminal ends (16) of the central support structure (12), and a plurality of blades (22) and / or channels (30) which extend axially. Each blade (22) and / or channel (30) is integrally mounted on the central support structure (12) between the two opposite end plates (14) and has an axial length (L) which is substantially equal to the axial distance between the two opposite end plates (14). Each blade (22) consists of a channel structure (30) which comprises a base wall (24) and a pair of radial walls (26, 28). The radial walls (26, 28) extend divergently from the respective base wall (24), such that the open surface of each channel structure (30) has an area greater than the area of the respective base wall (24).

Description

[0001] DEVICE FOR INTENSIFYING THE INTERCHANGE BETWEEN A LIQUID AND A TEXTILE MATERIAL IMMERSED IN A TANK CONTAINING THIS LIQUID

[0002] The present invention relates to a device for intensifying the interchange between a liquid and a textile material. More particularly, the present invention relates to a device for ecological washing of yarns and / or fabrics, preferably to be used in continuous or discontinuous dyeing lines, with indigo and other dyes, of the warp chains for denim fabrics, in flat, rope and loop systems.

[0003] It is specified that, in the present description, for the sake of simplicity of description, reference will be made only to operations of washing of yarns and / or fabrics dyed with indigo dye. However, the possibility of using the device according to the invention for other operations is not excluded, for example dyeing, bleaching and / or other complementary operations, and in general for all operations in which it is necessary to increase the interchange between a liquid and a textile material.

[0004] Denim, which is used especially to produce jeans and many other items of clothing, is nowadays one of the most widespread fabrics in the world: in its many types, it substantially satisfies the taste of all generations because of the particular features of its dyeing, which makes it possible to develop ever new fashion effects. However, throughout the textile industry, in addition to this unmatchable particular feature it has, denim also holds the unfortunate record of being the greatest consumer of water.

[0005] In the textile industry, and more specifically in the production of denim fabrics, water represents a fundamental component of use and greater consumption, in particular in the operations of the pre-treatments and post-treatments of the dyeing cycle. In fact, for these fundamental operations, all machines for continuous dyeing of warps, both in the so-called slasher dyeing and in so-called rope dyeing, are normally provided, upstream and downstream, with three or four washing tanks. The objectives of these operations, carried out with large quantities of water, which is almost always hot and partially purified, are the removal and elimination of all the impurities from the unrefined yarn, thus preparing it for the best dyeing condition. After the dyeing, said operations, again carried out with large quantities of water, permit the removal and elimination of the solvent and insolvent substances relating to the dyeing process, non-fixed dye, etc.

[0006] The efficiency of the washing, both as intermediate operations, and as final operations of a determined textile cycle, cannot be underestimated. In fact, very often, the efficiency of the washing is a determining factor both for the satisfactory outcome of the successive operations for the purposes of the quality of the product, and because these operations constitute a significant part of the processing costs. The urgent ecological and economic needs to reduce the consumption of water and thermal energy, and the requirement to be able to carry out more efficient washing, necessitated by the new wet finishing processes of the fabrics, as well as by the regulations intended to protect environmental sustainability, must lead to finding a solution to this problem.

[0007] As is known, denim is the particular fabric used for the production of jeans (or blue jeans) which, since approximately five thousand million pairs of them are produced annually, mean that the fabric is quantitatively the most used in the world. The cycle for production of the jeans, from the cultivation of the cotton until they reach the point of sale, in fact requires very high consumption of water and energy, as well as the use, in different production stages, of dyes and various chemical substances, the residues of which must be removed so that they do not come into contact with the consumers.

[0008] With the intention of reducing this large consumption of water and making the washing tanks according to the prior art more efficient, these washing tanks have gradually formed the basis of various updates, such as the counter-current supply between them, internal subdivision with several compartments in counter-current, the addition of pumps with sprayers or jets of water, etc. However, for one reason or another, all of these technical solutions have not achieved completely the objective set out. All of these technical solutions, including the one illustrated in document EP 3307935 A1 filed in the name of the same applicant, have consequently remained to a large extent unapplied, since they can be used only on the tanks of newly constructed machines, whereas on the other hand the several thousand tanks of the present machines in use are the ones which should be updated with devices which make their performance efficient, and reduce substantially the consumption of water.

[0009] It is specified that, although it has the same aim of the one according to the present invention, the device for intensifying the washing effect illustrated in document EP 3307935 A1 differs totally from the present device in terms of structure and possibility of use. In fact, as will be specified in greater detail hereinafter, the device according to the invention not only has a far simpler and therefore more economical structure, but above all it can be interchanged with the cylinders of all the present washing tanks of the machines for dyeing of warps which are currently in use, including those which are two-way. The device according to the present invention can be used universally, and its efficiency and positioning are independent from the direction of rotation. Its simple, free and totally open structure make it self-cleaning.

[0010] The device for intensifying the washing effect disclosed in document EP 3307935 A1 , on which the preamble of claim 1 is based, on the other hand has a very complex structure, and requires a minimum diameter, such as to make it impossible to position inside the traditional tanks currently in use, to replace their cylinders; in addition, its cost is very high. Its particularly complex structural shape requires assiduous cleaning in order to prevent clogging. Its efficiency and positioning are also indissolubly associated with the direction of rotation.

[0011] To summarise, the differences between the device for intensifying the washing effect illustrated in document EP 3307935 A1 and the device according to the present invention can be listed as follows. a1 ) Because of its particular shape, the structure of the device for intensifying the washing effect illustrated in document EP 3307935 A1 is complex, detachable and costly. It involves a central through bearing shaft with a square crosssection screwed onto it, four profiled longitudinal blades, and, at the two ends, two thick heads, which in turn bear 16 tubes with a circular cross-section, positioned radially such as to constitute the cylinder. The two heads are worked mechanically, not only in order to accommodate the 16 tubes in a fixed manner, but also to contain 8 windows each, which are necessary for the passage of the dye bath aspirated by the four blades positioned in the interior. a2) The structural design of the device according to the present invention is on the other hand far simpler and more economical. A plurality of longitudinal small tanks extending radially are secured on a central shaft, and at the two ends two end sheet metal plates are secured, in this case in order to prevent the dye bath from emerging without passing through the mat of yarn. b1 ) Again because of its particular shape, the device for intensifying the washing effect illustrated in document EP 3307935 A1 cannot be constructed below a minimum diameter of 200 / 220 mm, which makes it unusable on the dyeing machines already in use, which normally use cylinders with a diameter of 150 / 170 mm. b2) The device according to the present invention can be constructed in all the diameters of the cylinders normally in use on the dyeing machines of a known type, and in practice can be used universally. c1 ) Again because of its particular shape, the device for intensifying the washing effect illustrated in document EP 3307935 A1 can be used only in one direction. c2) The device according to the present invention can also be used on dyeing machines which work in alternating directions, such as jiggers, etc. d1 ) Again because of its particular shape, on the device for intensifying the washing effect illustrated in document EP 3307935 A1 , the corresponding operations of cleaning or washing when changing colour, etc., require a certain amount of attention and a considerable amount of time in order to prevent fouling and clogging. d2) On the other hand, the device according to the present invention, of practically open layout and with small tanks of truncated cone shape, is easy to clean and virtually unclogging and self-cleaning.

[0012] Other devices for intensifying the washing effect, of a known type, are disclosed, for example, in documents CN 1 15595756 A, CN 212834521 U, JP S52- 135675 U and GB 922302 A.

[0013] When a mat of yarn moves immersed in water, on its two opposite surfaces, in accordance with the laws of hydrodynamics, respective layers or films of liquid form, which run parallel to the yarn itself, and therefore without interchange with the yarn. In fact, this interchange takes place only in the so-called NIPs, i.e. in the short sections in which the yarn corresponds to the tangency with the guide cylinders (see the detail indicated as N in figure 2). In order to improve the washing of the yarn, it is therefore necessary to disturb the formation of these layers or films of liquid, and obtain the greatest possible turbulence in the bath. The ideal unit for washing the width of the yarns must have: maximum interchange of water / yarn, maximum removal of the insoluble substances, absolute compliance with the ordered layout of the threads, no energy consumption, and the minimum possible consumption of water.

[0014] The object of the present invention is thus to provide a device for intensifying the interchange between a liquid and a textile material which can resolve the aforementioned disadvantages of the prior art in a manner which is extremely simple, economical, ergonomic, ecological, and particularly functional.

[0015] In detail, an object of the present invention is to provide a device for intensifying the interchange between a liquid and a textile material which is applicable for any type of washing tank of the machines for continuous dyeing of warp chains, currently in use, and which autonomously, in other words without the use of pumps, nozzles, filters, etc., creates a high level of interchange between the liquid and the textile material (typically between the water and a mat of yarn), making the washing action as efficient as possible, and consequently making it possible to reduce drastically the consumption of water, thermal energy and products for purification of the water, in comparison with the devices according to the prior art.

[0016] Another object of the present invention is to provide a device for intensifying the interchange between a liquid and a textile material which does not require particular technical solutions and cannot become clogged, and therefore does not create problems for the ordered layout of the textile material when it is constituted for example by a mat of yarn.

[0017] A further object of the present invention is to provide a device for intensifying the interchange between a liquid and a textile material which guarantees the perfect uniformity of its action on the entire width of the textile material, when it is constituted for example by a mat of yarn.

[0018] Yet another object of the present invention is to provide a device for intensifying the interchange between a liquid and a textile material which does not require particular care or maintenance.

[0019] These objects according to the present invention are achieved by providing a device for intensifying the interchange between a liquid and a textile material as disclosed in claim 1 .

[0020] Further features of the invention are indicated by the dependent claims, which are an integral part of the present description.

[0021] In general, the device for intensifying the interchange between a liquid and textile material according to the present invention is particularly suitable for continuous treatment of chains of warp yarns and / or fabrics, and is substantially constituted by a particular structure with radial blades which, unlike the traditional cylinders with a solid, compact side surface, at each rotation imposes on the water it contains a hydrodynamic thrust which forces the water to pass through the mat of yarn which surrounds it for half of its circumference, thus obtaining a substantial washing effect.

[0022] In practice, this particular, simple device for intensifying the washing effect, in comparison with the traditional washing system which consists of passing the mat of yarn into the water, adds the innovative system of passing the water through the yarn. This particular device for intensifying the washing effect has dimensions identical to the cylinders of a known type mounted in the present washing tanks, both of the machines which carry out the dyeing in so-called slasher mode, and those which carry out the dyeing in so-called rope mode, and it can therefore be applied without any problem as a replacement for the cylinders of a known type.

[0023] In practice, when in a tank of a known type, such as, for example, the one illustrated in figure 1 , the respective cylinders are replaced by the devices for intensifying the washing effect according to the present invention, as well as their individual intensifications of the washing effect, these devices create all together the turbulence of all of the bath, thus preventing the formation of the layers or films of the bath itself, which normally run parallel to the yarn, thus permitting continuous interchange between the bath / fibre, i.e. a further increase in the washing effect. The continuous supply of replacement water can therefore be reduced drastically, indicatively by at least a half, and consequently the wastewater, compared with that of the normal tanks, will be quantitatively less but more concentrated with impurities, also with the advantage of reducing the cost of managing the final purification plant. It will be appreciated that the same reduction will also apply to the consumption of steam for heating the water, as well as to the products for purification thereof, with a further significant economic advantage.

[0024] To these ecological and economic advantages, there is also added that of obtaining a cleaner yarn, and consequently a fabric more suitable for wet finishing operations, with an increase in the qualitative performance levels. These particular devices for intensifying the washing effect are undoubtedly the most practical and simple means for washing better and with less water, in other words the solution to the pressing need to save a now precious commodity such as water which is a way of economising on it, thinking ahead to the future.

[0025] The device for intensifying the interchange between a liquid and a textile material according to the present invention can be applied to all plants and continuous processes for enhancing yarns and fabric, in particular, but not exclusively, to the washing tanks of machines for continuous dyeing of warps for denim fabrics.

[0026] The features and advantages of a device for intensifying the interchange between a liquid and a textile material according to the present invention will become more apparent from the following description provided by way of nonlimiting example, with reference to the appended schematic drawings, in which: figure 1 is a schematic view, in vertical cross-section, of a generic tank for treatment of textile materials by means of liquids; figure 2 is a schematic view, in vertical cross-section, of a cylinder according to the prior art for movement of textile materials inside a treatment tank such as the one in figure 1 ; figure 3 is a schematic view, in vertical cross-section, which shows the functionalities of a generic device for intensifying the interchange between a liquid and a textile material according to the present invention; figure 4 is a view in vertical cross-section which shows the basic configuration of a device for intensifying the interchange between a liquid and a textile material according to the present invention; figure 5 is a view in perspective of the device of figure 4 for intensifying the interchange between a liquid and a textile material; and figure 6 is another view in vertical cross-section of a possible variant of the device for intensifying the interchange between a liquid and a textile material according to the present invention.

[0027] With reference in particular to figure 1 , a generic tank is shown for the treatment of textile materials by means of liquids, which tank is indicated by the reference number 100 as a whole. The tank 100 is open at the top and is filled with a liquid W. Inside the tank 100 there are located one or more cylinders 200 of a known type, one of which is shown in detail in figure 2. The function of the cylinders 200 is to move the textile material T while it is immersed in the liquid W contained in the tank 100. The liquid W can for example be a washing bath or liquid for the textile material T. More particularly, this washing bath or liquid can be constituted by water. As previously indicated, as well as moving the textile material T, each cylinder 200 also permits the interchange between the liquid W and the textile material T, but only in the so-called NIP N shown in figure 2.

[0028] With reference now to figures 3 and 4, the basic configuration is shown of the device for intensifying the interchange between a liquid and a textile material, according to the present invention. The device for intensifying the interchange between a liquid and a textile material, or intensifier device, is indicated as a whole by the reference number 10.

[0029] The intensifier device 10 is configured to be rotated by the textile material T when this intensifier device 10 is immersed at least partially in the liquid W contained in the tank 100. The intensify device 10 is constituted by a body having cylindrical geometry, which comprises a central rod-shaped support structure 12. This central support structure 12 extends along an axial direction A which coincides with the axis of rotation of the body having cylindrical geometry. This central support structure 12 has a circular or polygonal transverse cross-section and can thus be obtained starting from a tubular element or a profile, which is preferably made of stainless steel. It is specified that in the present description, the terms “axial”, “radial”, “circumferential”, “central” and “side” always refer to positions of components with respect to the body having cylindrical geometry. It is also specified that “transverse cross-section” always means a cross-section perpendicular to the axial direction A.

[0030] The intensifier device 10 also comprises a pair of opposite end plates 14, which have the same circular shape. These two opposite end plates 14 are integrally mounted on the central support structure 12, at respective terminal ends 16 of this central support structure 12, such as to form the opposite bases of the body having cylindrical geometry. These two opposite end plates 14 thus protrude radially with respect to the central support structure 12, such as to define a predefined radial distance D1 (see figures 4 and 6) between the side surface 32 of the central support structure 12, and the circumferential edge 18 of each end plate 14. Each of the two opposite terminal ends 16 of the central support structure 12 protrudes axially with respect to a respective end plate 14, in order to form a respective rotation pin 20 for the body having cylindrical geometry, and thus for the intensifier device 10.

[0031] In its basic configuration in figures 3 and 4, the intensifier device 10 also comprises a plurality of blades 22 and / or channels 30 which extend axially, which protrude radially from the central support structure 12. Each of these blades 22 and / or channels 30 is integrally mounted on the central support structure 12, between the two opposite end plates 14, and has an axial length L which is substantially equal to the axial distance between the two opposite end plates 14.

[0032] According to a preferred variant of the present invention, shown in figure 6, each blade is constituted by a channel structure 30, comprising at least one flat or convex base wall 24, which is rendered directly integral with the central support structure 12, and at least one pair of radial walls 26, 28, which are integrally formed in a single piece with the base wall 24, which extend radially with respect to the base wall 24, and form the thrust elements for the liquid W, i.e. the blades themselves.

[0033] It is specified that the base wall 24 of each channel structure 30 can have a convex or flat shape, respectively according to the cylindrical or polyhedral shape of the side surface 32 of the central support structure 12. In turn, this cylindrical or polyhedral shape of the side surface 32 is caused respectively by the transverse circular or polygonal cross-section of the central support structure 12.

[0034] This configuration of the channel structure 30 makes it possible to simplify considerably the mechanical structure of the intensifier device 10. For economic and technical reasons, the central support structure 12 could be made from a solid metal profile with a round or polygonal transverse cross-section, from which there are obtained by turning the end rotation pins 20, and on which the blades 22 and / or the channel structures 30 are secured directly. For example, on the basis of this configuration, each channel structure 30 can be secured directly on the central support structure 12 by means of simple operations of welding and / or screwing of the respective flat or convex base wall 24, onto a corresponding flat or convex side surface 32 of this central support structure 12.

[0035] It is also specified that, as shown in particular in figure 6, between the radial walls 26, 28 of contiguous channel structures 30, interspaces 36 are provided which have the same function as these channel structures 30, such that, on a single device 10, the intensification of the interchange between the liquid W and the textile material T can be carried out simultaneously both by a predefined number of channel structures 30, and by the same number of interspaces 36 or further channels which are formed between these channel structures 30. For example, on the basis of the embodiment of the intensifier device 10 shown in figure 6, this device 10 is provided with twelve cavities or channels separated from one another by the same number of radial walls 26, 28. The direction of the liquid W which passes through the textile material T is indicated by the arrows in figure 3.

[0036] Preferably, for structural simplicity, each channel structure 30 comprises a single flat or convex continuous base wall 24 which has an axial length L substantially equal to the axial distance between the opposite end plates 14. Consequently, each radial wall 26, 28 is also continuous and has an axial length L which is substantially equal to the axial distance between the two opposite end plates 14. Again preferably, the radial walls 26, 28 of each channel structure 30 extend divergently starting from the respective base wall 24, such that the open surface of each channel structure 30 has an area greater than the area of the respective base wall 24.

[0037] The structural simplicity of the intensifier device 10 also consists in the fact that each channel structure 30 can be manufactured starting from a single sheet of metal plate. The flat or convex base wall, and the radial walls 26, 28 of each channel structure 30 can thus be obtained by means of an operation of bending this single sheet of metal plate.

[0038] According to a preferred aspect of the present invention, each blade 22 and / or each of the radial walls 26, 28 of each channel structure 30 has a length D2, measured in a radial direction, which is smaller than, or equal to, the radial distance D1 between the side surface 32 of the central support structure 12 and the circumferential edge 18 of each end plate 14. In other words, none of the blades 22 and / or of the radial walls 26, 28 of each channel structure 30 is configured to protrude from the overall side surface of the body having cylindrical geometry which constitutes the intensifier device 10. In addition, as shown for example in figure 6, the terminal edge 34 of each radial wall 26, 28 can preferably be obtained by means of an operation of edging of the individual sheet of metal plate which forms each channel structure 30, such that each terminal edge 34 is rounded, and has greater stiffness than the average stiffness of each radial wall 26, 28. All of these technical features of the intensifier device 10 contribute to preventing any potential damage to the textile material T when it is wound around the body having cylindrical geometry which constitutes the intensifier device 10.

[0039] The intensifier device 10 described so far can thus be used efficiently inside any tank 100 which is designed to carry out operations of treatment on a textile material T by means of a liquid W. The tank 100 can be of any type known in the prior art, such as, for example, the one shown in figure 1 , which is open at the top and is filled at least partially with the liquid W. Each of the intensifier devices 10 is at least partially immersed in the liquid W, and rotates around its own axis A in order to define a guided path for the textile material the inside the liquid W, when the textile material T is wound at least partially around each of the intensifier devices 10.

[0040] It has thus been shown that the device for intensifying the interchange between a liquid and a textile material according to the present invention achieves the aforementioned objects, in particular obtaining the following advantages:

[0041] - possibility of universal use, including on two-way machines;

[0042] - maximum efficiency of washing;

[0043] - total elimination of the pigmented dye;

[0044] - complete cleaning of the yarn;

[0045] - considerable reduction of the consumption of water, thermal energy, and products for purification of the water;

[0046] - reduction of the costs and the environmental impact;

[0047] - technological improvements in the final treatments of the fabric;

[0048] - commercial advantages (improved visual appearance of the fabric, white weft);

[0049] - absence of filters and clogging (the device is self-cleaning).

[0050] In the device for intensifying the interchange between a liquid and a textile material according to the invention, the materials used, as well as the shapes and dimensions, can be of any type according to the technical requirements.

[0051] The scope of protection of the invention is thus defined by the appended claims.

Claims

CLAIMS1. A device (10) for intensifying the interchange between a liquid (W) and a textile material (T), the device (10) being configured to be rotated when at least partially immersed in the liquid (W) contained in a tank (100), the device (10) consisting of a body having cylindrical geometry which comprises:- a central rod-shaped support structure (12), which extends along an axial direction (A) coinciding with the axis of rotation of the body having cylindrical geometry, which has a circular or polygonal cross-section, and which is obtained starting from a tubular element or a profile;- a pair of opposite end plates (14), which have the same circular shape, which are integrally mounted on the central support structure (12) at respective terminal ends (16) of said central support structure (12), so as to form the opposite bases of the body having cylindrical geometry, and which protrude radially with respect to said central support structure (12), such as to define a predefined radial distance (D1 ) between the side surface (32) of said central support structure (12) and the circumferential edge (18) of each end plate (14), wherein each of the two opposite terminal ends (16) of said central support structure (12) protrudes axially with respect to a respective end plate (14) in order to form a respective rotation pin (20) for said body having cylindrical geometry; and- a plurality of axially extending blades (22) and / or channels (30), wherein each blade (22) and / or channel (30) extends radially from the central support structure (12), is integrally mounted on said central support structure (12), between the two opposite end plates (14), and has an axial length (L) which is equal to the axial distance between said two opposite end plates (14), the device (10) being characterized in that each blade (22) consists of a channel structure (30) which comprises:- at least one flat or convex base wall (24), which is made directly integral with the central support structure (12); and- at least one pair of radial walls (26, 28), which are integrally formed in a single piece with the base wall (24), which extend radially with respect to said base wall (24) and form the thrust elements for the liquid (W), wherein the radial walls (26, 28) of each channel structure (30) extend divergently starting from the respective base wall (24), in such a way that the open surfaceof each channel structure (30) has an area greater than the area of the respective base wall (24).

2. The device (10) according to claim 1 , characterized in that each channel structure (30) is attached to said central support structure (12) by means of welding and / or screwing of the respective base wall (24) onto the side surface (32) of said central support structure (12).

3. The device (10) according to claim 1 or 2, characterized in that each channel structure (30) comprises a single continuous base wall (24), which has an axial length (L) equal to the axial distance between said two opposite end plates (14), wherein each radial wall (26, 28) is also continuous and has an axial length (L) which is equal to the axial distance between said two opposite end plates (14).

4. The device (10) according to any one of claims 1 to 3, characterized in that each channel structure (30) is manufactured starting from a single sheet of metal plate, wherein the base wall (24) and the radial walls (26, 28) of each channel structure (30) are obtained by means of a bending operation for bending said single sheet of metal plate.

5. The device (10) according to any one of claims 1 to 4, characterized in that each of said blades (22) and / or each of the radial walls (26, 28) of each channel structure (30) has a length (D2), measured in a radial direction, which is smaller than, or equal to, said radial distance (D1 ).

6. The device (10) according to claim 5, characterized in that the terminal edge (34) of each radial wall (26, 28) is obtained by means of an edging operation for edging said single sheet of metal plate, in such a way that said terminal edge (34) is rounded and has a stiffness which is greater than the average stiffness of each radial wall (26, 28).

7. A tank (100) designed to carry out treatment operations on a textile material (T) by means of a liquid (W), said tank (100) being open at the top and being at least partially filled with said liquid (W), said tank (100) being characterized in that one or more devices (10) according to any one of claims 1 to 6 are rotatably placed in its interior, said devices (10) being at least partially immersed in said liquid (W) and being configured to define a guided path for the textile material (T) inside said liquid (W) when said textile material (T) is at least partially wound around each of said devices (10).

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