A new generation textile processing machine

Abstract

The invention is a new generation textile processing machine comprising a main drum (32) and a drum (34) that ensure the movement of textile materials, a circulation pump (1) which allows adjustment of the flow rate, volume, and pressure of the liquid circulation via its drive, an air fan (21) which allows adjustment of air flow rate, pressure, and speed via its drive and ensures air circulation, a nozzle system (33) that directs process liquid to every point of textile material loading areas, a proportional valve (2) that controls the amount of liquid passing through the bypass line of the mixing system, a heat exchanger (15) that ensures the process liquid reaches the set value during the mixing process, a steam valve (3) that activates or deactivates steam entry into the heating system located inside the main tank for circulating the process liquid without using the bypass or flotte mixing line, a water inlet valve (4) that activates or deactivates the cooling system located inside the main tank, and a dye preparation tank (16) prepared for dosing and transferring the dye substance.

Description

Title of Invention : A New Generation Textile Processing MachineTechnical Field[1] This invention relates to a new generation textile processing machine developed to allow various forms of textile materials to undergo processing in the same process bath, enabling quick processing times in wet textile finishing operations, and achieving water, energy, and chemical savings during wet finishing processes. It is designed to monitor finishing processes without surface problems such as crease, friction, and deformation occurring during wet finishing operations, before the textile product from the textile operation is ready for sale.Background Art[2] Currently, finishing processes such as pre-treatment, dyeing, and washing of fabrics are commonly carried out in rope form in HT Jet and HT airflow machines. Processing fabrics in rope form can often lead to surface problems such as creases.[3] In the known art, in the HT Jet fabric dyeing machine, the fabric's rotational movement occurs through the reel and the movement of the circulated liquid. During the fabric's movement, there are warning systems for fabric wrapping around the reel due to reasons such as the fabric wrapping a full turn, stopping the rotational movement. Instances where the fabric knots, gets stuck, or breaks during the process can lead to process delays. Additionally, there is a possibility of surface problems such as friction and pilling occurring during processing.[4] In other known art, in the German patent DE19548862A1 concerning HT air flow machines, fabrics also undergo processing in rope form, where the fabric's movement occurs alongside the effect of air near the reel. There is a possibility of encountering problems such as fabric getting stuck during the process, which could potentially result in surface issues on the fabric.[5] In HT Jet and HT air flow machines, the point where the rotating fabric meets the process liquid is positioned in the upper section of the main tank, and the circulated process liquid needs to be transported up to the level of the nozzle. Asthe diameter of the pipes used for the path and installation of the process liquid increases, the amount of process liquid required also increases. Consequently, water consumption, chemical consumption determined by the amount of water, and the amount of energy required for heating the process liquid also increase.[6] In the aforementioned jet fabric dyeing machines and airflow dyeing machines, processing of textile materials that cannot be brought into rope-like forms such as piece fabrics is not feasible.[7] In beam dyeing machines described in US Patent No. US3100979A, which pertains to another known technique, the fabric is loaded onto beams and processes are conducted with the fabric wound onto the main tank. In this system where the process liquid is mobile and the fabric is stationary, the process liquid level needs to be positioned above the fabric wound onto the beams. These systems do not carry the risk of crease but can encounter dyeing irregularities at the edges and middle of the beams. Additionally, piece dyeing cannot be performed on these machines.[8] In piece dyeing machines described in US Patent No. US20130219971A1 , which pertains to another known technique, operations can generally be conducted in piece form, such as garments. Long length fabrics are not wound onto machine elements; instead, materials to be processed are filled into a tank.Objectives of the Invention[9] Our invention aims to enable various textile materials in different forms to undergo processing in the same process bath.

[0010] Another objective of the invention is to ensure short processing times in wet finishing processes.

[0011] Yet another objective of the invention is to reduce production costs such as water, energy, and chemical savings during wet finishing processes.

[0012] Another objective of the invention is to enable monitoring of finishing processes on materials (especially fabrics) without surface problems such as crease, friction, and deformation occurring.

[0013] Our invention, the new generation textile finishing machine, is described in the attached figures as follows:Figure 1 : Side perspective view of the new generation textile finishing machine.Figure 2: Perspective view of the new generation textile finishing machine.Figure 3: Rear perspective view of the new generation textile finishing machine.Figure 4: Cross-sectional view of the new generation textile finishing machine.Figure 5: Perspective view of the main drum (32).Figure 6: Cross-sectional view of the main drum (32).Figure 7: Perspective view of the drum (34).Figure 8: Detailed perspective view of the drum (34).

[0014] The components comprising the structure of the new generation textile finishing machine depicted in the figures and the significant details on these components are numbered accordingly and listed below:1- Circulation pump2- Proportional valve3- Steam valve4- Water inlet valve5- Dosing valve6- Dye tank pump discharge valve- Dye tank circulation valve - Main Tank-Dye Tank transfer valve - Dye tank heating valve 0- Dye tank water fill valve 1- Main tank water fill valve 2- Pressure relief valve 3- Safety valve 4- Dye tank circulation pump 5- Heat exchanger 6- Additional tank 7- Chemical and dye tank 8- Bypass valve 9- Air cooling heat exchanger 0- Separator 1- Fan 2- Air heating heat exchanger 3- Cooling water inlet valve 4- Steam inlet valve 5- Air cooling heat exchanger bypass valve6- Main tank air inlet selection valve 7- Check valve 8- Inner drum drive motor 9- Main tank 0- Pressure transmitter 1- Pump suction filter 2- Main drum 3- Nozzle34.1- Drum loading area34.2- Drum outer part34.3- Drum mirrorDetailed Description of the Invention

[0015] Our invention, the new generation textile finishing machine, primarily consists of the main drum (32) and drum (34) which ensure the movement of textile materials, a circulation pump (1) that allows adjustment of the flow rate, flow volume, and pressure of liquid circulation via its associated driver, an air fan (21) that enables adjustment of air flow rate, pressure, and speed via its associated driver for air circulation, a nozzle system (33) that directs process liquid to every point in the loading areas of textile materials, a proportional valve (2) that adjusts the flow rate of water passing through the installation when in an open position and regulates the amount of liquid passing through the mixing line to activate or deactivate the line and ensure the homogenization of the process liquid in a short time during mixing operations, a heat exchanger (15) that ensures the process liquid reaches the set temperature value during mixing operations, a steam valve (3) that activates or deactivates steam input to the heating system located within the main tank without using a bypass or flotte mixing line for the circulated process liquid, a water inlet valve (4) that activates or deactivates the cooling system located within the main tank, and a dye preparation tank (16) prepared for dosing and transferring dye materials.

[0016] In our invention, circulation of the process liquid is achieved using circulation pump (1), which regulates flow rate, flow rate volume, and pressure, while air circulation is handled by fan (21), which adjusts air flow rate, pressure, and velocity. By spraying the process liquid onto textile material along with compressed air, the flow velocity of process liquid molecules increases, enhancing the penetration capability of the liquid in pulverized form into the textile material. The increased molecule velocity of the process liquid allows the circulation liquid to operate at lower revolutions, enabling operation with less process liquid, thereby reducing production costs.

[0017] In HT airflow machines, pumps performing circulation at lower flow rates are used. Liquid circulation at a rate of 20 m3 / h is provided, whereas in HT jet machines, pumps circulate 100 m3 / h of liquid. Despite using less water in HT airflow machines, there are no penetration capability issues.

[0018] For textile finishing processes in our invention:- Selection of the process is made based on factors such as textile material type, planned processes for the material, color, fastness, etc.,- Loading of goods is carried out;-Loading is done in the loading area (34.1) for materials not wound on the main drum (32),-Material folded in the weft direction to be wound around the drum (32) surface of the main drum (32) with drum rotation,-During winding, optionally spraying process liquid onto the fabric surface,- Selection of programs created based on previous trials without any issues on the fabric surface using the programmer, considering the amount of textile material or fabric, type of fabric, color, type of process to be performed... and starting the program,- Execution of pre-treatment, dyeing, washing, and other finishing processes,- Draining the final bath after finishing processes are completed,- Squeezing with drum rotation to remove excess water from the material surface,These steps constitute the process.

[0019] Textile materials such as fabric or other textile materials are loaded onto the feeding area of the main drum (32), allowing for a transition of the liquor from above the loading area to below or vice versa, depending on the process, with adjustable rotational speed and direction. If the textile material to be loaded is fabric, its tension is adjusted when folded in a single layer, two layers folded in the weft direction (across the width of the fabric), three layers folded in the weftdirection, four layers folded in the weft direction, or eight layers folded in the weft direction.

[0020] During the rotation of the main drum (32) with the stacked fabrics, the squeezing effect on the lower fabric ensures that the process liquid on the material reaches the suction line of circulation pump (1) more quickly and at a higher rate.

[0021] In the nozzle (33) systems, the position closest to the suction line of the circulation pump (1) and the liquid circulation pump (1) is located, shortening the path of the process liquid during circulation.

[0022] During the process, when the main drum (32) rotates rapidly due to centrifugal force, the squeezing function is performed, which can optionally stop the flow of process liquid. The rotation speed of the main drum (32) is controlled by the internal drum drive motor (28), and the process is carried out to remove substances such as liquids, dyes, oils, waxes, dirt, etc., from the textile material.

[0023] Processing the fabric folded in the weft direction reduces the processing surface area per unit area, thereby reducing the use of process liquid. This results in savings in chemicals, water, energy, dye, etc., and reduces processing costs.

[0024] Furthermore, space is saved compared to machines operating in an open width format, allowing textile materials to be stacked for processing. This results in a higher throughput of textile materials treated with process liquid per unit time compared to machines operating without stacking or in a single layer / rope format, thereby reducing processing time.

[0025] During the rotation of the main drum (32) with the stacked fabrics, the squeezing effect on the lower fabric ensures that the process liquid on the material reaches the suction line of circulation pump (1) more quickly and at ahigher rate, allowing for faster achievement of a homogenous mixture of process liquid.

[0026] By accelerating the circulation of process liquid, less process liquid is used, thereby reducing production costs.

[0027] Nozzle (33) systems are positioned closest to the suction line of the main drum (32) circulation pump (1) and the liquid circulation pump (1), allowing for shorter paths for process liquid circulation compared to other HT Jet and HT airflow fabric machines, enabling processes to be completed in less time and with less process liquid.

[0028] The short circulation line prevents temperature, heat, flow, and pressure losses that may occur in the system, reducing production costs, and also prevents problems due to temperature variations and fluctuations in the circulation line of the process liquid, minimizing losses in product quality.

[0029] In systems where process liquid circulation is achieved with air-liquid mixture, fabric movement is supported by airflow, but in some processes, chemicals lose their effectiveness due to air effects, leading to decreased process efficiency. In the textile finishing machine of the present invention, liquid circulation is achieved without using an air circulation system, where only the liquid is adjusted to the desired flow rate and pressure and transferred onto the material to conduct the process. This allows processes to be conducted at the desired quality using chemicals that may lose efficiency in airflow.

[0030] Each nozzle (33) system is individually controlled to direct liquid flow from inside to outside the drum (34) or vice versa according to the processes, enabling the liquid flow sent to nozzles (33) to be active or passive.

[0031] During the process, the rapid rotation of the main drum (32) and the centrifugal effect achieved by the squeezing function stop the flow of process liquid. The rotation speed of the main drum (32) is adjusted by the internal drumdrive motor (28), allowing the process to be monitored for liquids, dyes, oils, waxes, dirt, etc., that are intended to be removed from the textile material.

[0032] The main drum (32), with perforated inner and side surfaces, allows for increased loading of textile materials that can be wrapped around it, enabling the spraying of process liquid onto the material wrapped on the surface of the main drum (32) through nozzles positioned inside and outside the drum, allowing for better observation of processes.

[0033] The loading area of the drum (34.1), with perforated inner and side surfaces, feeds non-wrappable pieces and garments, while the outer surface of the drum(34.2), which is solid, feeds materials like fabric that can be wrapped around the drum for processing.

[0034] Multiple loading areas (34.1) are available for different types of textile materials that cannot or are not desired to be wrapped around the drum due to process efficiency, quality reasons, etc., while the outer surface of the drum(34.2) ensures that materials like textile materials desired to be wrapped around it or treated without wrapping are directed towards the suction line of circulation pump (1), which acts as a faster process liquid collection area, by preventing the passage of air and process liquid to the non-wrapped area of the drum outer surface (34.2).

[0035] The airflow and liquid flow are designed to be sprayed onto the surface of the material loaded onto the drum (34) from the center of the drum, towards the material surface intended for non-wrapping processing, and onto the upper surface of the material wrapped around the outer surface of the drum (34.2). During the process, drum mirrors (34.3) are placed to the right and end of the drum (34) to prevent fabric or textile material wrapped around the outer surface of the drum (34.2) from sliding off the drum (34), ensuring that even in contact with the drum mirror (34.3), nozzles (33) are positioned to expose the process liquid to the fabric surface, enabling sufficient transfer of process liquid to the fabric surface even if tension occurs or sliding over each other during finishing processes, preventing problems that may arise in the process.Portable chemical and dye tank (17)

[0036] Tank to the portable chemical and dye tank (17) designed for samples or low-capacity machines, necessary chemicals and dyes for the process can be prepared independently from the machine and attached to the additional tank (16), integrating with the dosage system. This eliminates chemical and dye losses that may occur during transfer processes to the dye, chemical, or additional tanks of the machine, providing operational convenience. Positioned on the additional tank (16), it allows direct dosing of the chemicals and dyes into the desired amount to the tank below.

[0037] Eliminating the need for dilution systems, additional dosage, transfer pumps, and dosage installations saves space, prevents the use of clean water to clean the chemicals in the dosage installation, and saves energy by eliminating pump operations during transfer and dosage processes.Process Liquid Heating I Cooling System

[0038] Our invention includes two process liquid heating / cooling systems. The main tank (29) heating system is located on the suction side of the main tank's (29) circulation pump (1), with heat exchangers (15) positioned on the process liquid mixing / bypass system, controlled via PLC by opening and closing proportional valves (2) to perform processes.

[0039] The process liquid heating / cooling systems can operate separately or together. Designed to prevent problems arising from direct spraying of heated process liquid onto textile materials, the heat exchanger (15) systems enable faster process liquid heating / cooling operations when used simultaneously, while allowing processes to be carried out with less process liquid without using the heat exchanger system (15) in the bypass line according to the process, reducing chemical, energy, dye, water consumption, etc.Air Circulation System

[0040] The air system in the new generation textile finishing machine has separate purposes for wet and drying processes. In finishing processes, spraying the air-liquid mixture onto the textile material increases the flow rate of process liquid molecules and enhances the penetration of the liquid into the textile material through a pulverizing effect. Additionally, using less process liquid contributes to reducing production costs.

[0041] For drying processes after finishing processing, the air circulation system draws moist air from the main tank (29) through the cooling heat exchanger (19) to reach the separator (20). Here, condensed liquid is separated from the drying air by the separator (20), allowing highly moisture-retentive air to pass to the fan(21). The high moisture-retentive air heated by the air heating heat exchanger(22) between the fan (21) and the main tank (29) is directed to the nozzles (33) positioned in various zones of the main drum (32) inside the main tank (29). Drying processes for textile materials are achieved through the circulation of air.Proportionally Adjustable Mixing and Circulation System (By-pass Line)

[0042] The system incorporates a proportional valve (2) located on the by-pass and main tank (29) dye tank transfer line to adjust the flow rate required for mixing the process liquid, thereby regulating the flow rate and volume of liquid on the by-pass line. Adjusting the flow rate of the process liquid on the by-pass line to the desired proportion reduces the amount of liquid necessary for the liquid circulation system, contributing to reducing production costs. Additionally, the flow rate of the liquid in the feed line (33) on the same installation enhances flow rate values, enabling the circulation pump (1) to operate at lower speeds and thus achieve energy savings.

Claims

AMENDED CLAIMS received by the International Bureau on 23 October 2024 (23.10.2024)1. The invention is a new generation textile processing machine, characterized by comprising: a main drum (32) and a drum (34) that primarily ensure the movement of textile materials; a circulation pump (1) which allows adjustment of the flow rate, volume, and pressure of liquid circulation via its connected driver; an air fan (21) which allows adjustment of air flow rate, pressure, and speed via its connected driver and ensures air circulation; a nozzle system (33) that directs process liquid to every point of textile material loading areas; a proportional valve (2) that controls the amount of liquid passing through the mixing system (by pass) line; a heat exchanger (15) that ensures the process liquid reaches the set value during the mixing process; a steam valve (3) that activates or deactivates steam entry into the heating system located inside the main tank for circulating the process liquid without using the bypass or liquor mixing line; a water inlet valve (4) that activates or deactivates the cooling system located inside the main tank; and a additional tank (16) prepared for dosing and transferring the dye substance.

2. A new generation textile processing machine according to Claim 1, characterized by: including a nozzle system (33) positioned closest to the suction line of the circulation pump (1) and thus closest to the main drum, separately controlled via pneumatic systems, enabling the activation or deactivation of liquid flow sent to processes based on the process.

3. A new generation textile processing machine according to any of the above claims, characterized by: comprising a perforated main drum (32) with its inner and side surfaces perforated, equipped with nozzles (33) positioned on its inner and outer surfaces, and a nozzle system that sprays process liquid to enable liquid transition through the perforated drum to the area where the fabric is wrapped. The nozzle system sprays liquid on both the inner and outer surfaces.

4. A new generation textile processing machine according to any of the above claims, characterized by: comprising a perforated drum (34) with its loading area (34.1) for loading non-wrappable materials and accessories, its outer part (34.2) perforated for wrapping fabric or textile material, ensuring simultaneous wet and dry processing of materials that can be wrapped or not, with drum mirrors (34.3) on the right and left15AMENDED SHEET (ARTICLE 19)sections to prevent fabric or textile material from protruding from the drum outer part (34.2).

5. A new generation textile processing machine according to any of the above claims, characterized by: including a heat exchanger (15) positioned on the mixing line for temperature control, usable separately according to the process, in the delivery line of the circulation pump (1).

6. A new generation textile processing machine according to any of the above claims, characterized by including a proportional valve (2) controlled via PLC on the mixing / bypass system to open and close, thereby regulating the passage of the liquid and ensuring rapid homogenization of the process liquid during the mixing process.

7. A new generation textile processing machine according to any of the above claims, characterized by: including a separator (20) through which humid air extracted from the main tank (29) passes after passing through a cooling heat exchanger (19).

8. A new generation textile processing machine according to any of the above claims, characterized by: including a portable chemical and dye tank (17) that can be independently prepared for chemicals and dye substances necessary for processes and can be connected again to the additional tank (16), suitable for samples or low-capacity machines.

9. A new generation textile processing machine according to any of the above claims, characterized by: including two separate heating and two separate cooling systems with separate steam and water inlets.

10. A textile finishing processing method with a new generation textile processing machine, characterized by the following steps;- Selection of processes based on factors such as textile material type, intended processes for the material, color, durability, etc.,- Loading of the textile materials;- Loading materials onto the drum loading area (34.1) is provided for textiles that are not wrapped around the main drum (32), while operations involving wrapping around the drum surface utilize drum (32),16AMENDED SHEET (ARTICLE 19)- Wrapping of folded material intended for wrapping around the drum (32) folded in the weft direction,- Spraying process liquid onto the fabric surface as desired during the wrapping process,- Selection of programs created through trials conducted previously on the fabric surface via the programmer, considering factors such as the amount of textile material or fabric to be processed, fabric type, color, type of operation to be performed... and starting the program,Execution of pre-treatment, dyeing, washing, and other finishing processes, Draining of the final bath after finishing processes are completed,- Squeezing operation, with the rotation of the drum, to remove excess water from the material, without relying on air pressure, the process can be adjusted to use or not use the air circulation function as needed, additionally, the term for the removal of water from the material can be included, comprising these process steps.17AMENDED SHEET (ARTICLE 19)

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