Dyeing booth

Abstract

The invention relates to a dyeing booth for continuous dyeing of narrow fabrics, which is operated by a microwave system to ensure a uniform binding reaction of the dyestuff to the fabric, and to a method of operation of the booth.

Description

[0001] DESCRIPTION

[0002] DYEING BOOTH

[0003] Technical Field

[0004] The invention relates to a dyeing booth for continuous dyeing of narrow fabrics, which is operated by a microwave system to ensure a uniform binding reaction of the dyestuff to the fabric, and to a method of operation of the booth.

[0005] State of the Art

[0006] Textile dyeing is an industry with high water and energy consumption. Today, shrinkage and more commonly continuous systems are used in the dyeing and finishing processes of narrow fabrics. In continuous dyeing, the dye fixing process takes place in the hot air chambers of the dyeing machines with resistance, saturated steam supply, which can operate with electricity- gas-steam.

[0007] For saturated steam supply, it is necessary to install the infrastructure of steam boilers and transportation lines during the factory installation phase and to operate them continuously during production. There are energy losses in the transportation lines, there may be a safety problem in the transition areas of the lines and it increases the working environment temperature.

[0008] In the current continuous dyeing process, the dyeing process can be started after the steam and temperatures in the hot air room-cabin reach 95-120°C and are determined to be in balance. When dyeing is started without temperature and steam equilibrium, the dye does not fix properly to the fabric, and problems such as unlevelness-color differences-fastness etc. occur. In order for the dyeing system and lines to reach equilibrium, the system must run empty without production for at least four hours. Since time, production losses and energy consumption are very high in the existing continuous dyeing booths, they are not suitable for open-close, batch, flexible operation and low-quantity production.

[0009] Since the fixation of the dye to the fabric takes place in a steamy, hot air booth, problems such as beginning-ending difference, color transitions, unlevelness, decrease in wet fastness values occur in the slightest change in the booth. Because in the existing dyeing booths, it is expected that the machine and infrastructure systems are operated and the desired dyeing conditions are formed and stabilized. In the known narrow size fabric dyeing booths, the dyeing speed is 14- 16 m / min.

[0010] In the current system, there are various patent or utility model applications and articles on the subject. One of them is the application numbered "CN107974784A". Said application discloses a microwave dyeing apparatus and a microwave dyeing method. The microwave dyeing apparatus includes a cavity for holding a dyeing bath solution and a microwave signal source for emitting microwave signals into the cavity for dyeing textiles. It is stated that with the invention, the dyeing process time and cost can be reduced, the dyeing color degree of the textile can be effectively improved, waste water generation can be reduced and environmental damage can be avoided.

[0011] The application numbered "CN103276613 A", which is in the known state of the art, discloses a dyeing method for performing a color fixing process in the microwave on two types of pure cotton fabrics. The dyeing process and the chemical substances used in the reactive dyeing of cotton fibers in a microwave environment with a group of reactive dyestuffs that dye cotton fibers at high temperature according to both the shrinkage and exhaust method are specified. In the shrinkage method, while the fabric and auxiliary chemicals were in the dye bath, the bath was heated by microwave method and the dyeing process was carried out. In the exhaust dyeing method, the dyeing of cotton fabric with high temperature reactive dyestuff group was limited. The fabric was passed through the dye bath, 80% by weight of the dye bath solution was impregnated on the fabric, then the fabric was pre-dried at 90 degrees for 1.5 minutes and microwave dye fixation was performed. Microwave fixation time is not specified. After dye fixation, reactive washing processes are applied to the fabric. End of dye wash baths are suitable for dyeing cotton fabric with reactive dyestuffs and in this respect, the application area is very limited.

[0012] The application numbered "CN101649563 A" in the known state of the art discloses a method of color fixation in microwave for buffer dyeing of wool at room temperature. The group of reactive dyestuffs that dye wool fiber at high temperature in microwave environment, the dyeing process according to the exhaust method with mordant dyestuffs and the chemical substances used in reactive dyeing are specified. The present invention is limited to wool fiber- reactive and mordant dyestuffs. The fabric was impregnated with 80-120% of the dye and fixed in a microwave environment for 1-6 minutes at 300-700 W power and reactive dye washing baths were started. Urea, thiocarbamide was used as solvent in the invention. Chemicals such as sodium hydrogensulfite, sodium sulfite, sodium pyrosulfite etc. were used as reductants.

[0013] The application numbered "TR 2008 / 05371", which is in the known state of the art, is related to a velvet fabric dye booth. With the invention for the purpose of dyeing velvet fabric in small quantities, high quality and efficient, and in a structure that will cause the least damage to the environment; a pressurized dye booth with a suitable structure has been created. The characteristic of the pressure dyeing booth is that it is in the form of a rectangular prism, it is installed at the ground level of the enterprise in order to load fabric directly into it, it has a showering system with a perforated showering chamber, and it contains a structure that can rotate the cylindrical fabric hanger hoop, which is placed on the cylindrical fabric hanger hoop and the cylindrical fabric hanger hoop on the cylindrical fabric hanger hoop, by means of at least one reducer or rear left and front right reducers.

[0014] In the current system, as can be seen from the above applications, in the continuous dyeing process of narrow fabrics, the reaction of the dyestuff binding to the fiber takes place in booths with steam and electric resistance heating systems. There is no commercial microwave dyeing booth application in this field.

[0015] In the existing system, since the resistances are affected by saturated steam, there are frequent breakdowns, causing maintenance costs, time and production losses. Energy losses increase due to calcification on the resistances. Thermal imbalances may occur while the resistances provide heating on the lateral surfaces in the dyeing booth. In order to prevent this, thermal balance is created by giving more steam to the environment. This situation causes an increase in steam consumption. In addition, since the dyeing process can be started after the temperature (95- 120°C) and saturated steam systems reach equilibrium in the dyeing booths, the dyeing booths must be operated for at least 4 hours without production. This type of dyeing systems is not suitable for batch and low production quantities as time, production losses and energy consumption are very high.

[0016] In the current system, there are also many malfunctions as the resistances are affected by saturated steam. While the dyestuff is fixed to the fabric in the dyeing booth, the slightest temperature and steam amount changes in the booth cause beginning and ending color differences, color continuity between productions and unlevelness problems. Energy infrastructure installation costs of existing systems are very high. The textile dyeing production work areas in the current system are humid and hot, affecting employee health due to steam and heat emission.

[0017] As a result, due to the negativities described above and due to the inadequacy of the existing solutions on the subject, there is a need for a dyeing booth operating with a microwave system to ensure a uniform binding reaction of the dyestuff to the fabric in the continuous dyeing system of narrow-sized fabrics.

[0018] Brief Description and Objectives of the Invention

[0019] The invention relates to a dyeing booth for continuous dyeing of narrow fabrics, which is operated by a microwave system to ensure a uniform binding reaction of the dyestuff to the fabric, and to a method of operation of the booth.

[0020] In the microwave dyeing booth developed with the invention, a homogeneous dyeing can be performed and a dyed fabric without unlevelness, with high color repetition and better wet fastness can be obtained.

[0021] The aim of the invention is to reduce the dyeing reaction time. For this purpose, the microwave dyeing booth developed in the invention selectively heats only the dye-impregnated fabric and the dyeing reaction time is shortened since the dyeing reaction can be carried out quickly by creating a uniform heat in the microstructure of the fiber.

[0022] A further object of the invention is to enable operation even without waiting for the necessary environmental conditions. In the developed microwave dyeing booth, only the selective heating system for the fabric can be operated on-off, intermittently, without waiting for the dyeing ambient conditions to reach equilibrium.

[0023] Another aim of the invention is to prevent time and energy losses. With the dyeing booth developed with the invention, time and energy losses in existing dyeing booths are prevented. Since it is a modular dyeing booth that can be opened and closed at any time, a more economical and waste-load-reducing dyeing booth has been developed for batch and short-quantity narrowsized fabric dyeing.

[0024] Another object of the invention is to prevent the radiation generated in the booth during the process from being emitted to the outside. For this purpose, the microwave booth is isolated in such a way as to prevent the radiation inside the booth where the dyeing reaction is carried out from spreading outside. With this isolation, there is also no vapor emission and heat emission to the production area outside the microwave dyeing booth. In this way, working conditions are better in terms of employee health.

[0025] With the invention, a green dyeing booth and process has been developed that reduces dyeing time, production losses, energy costs and carbon footprint.

[0026] Description of the Figures

[0027] Figure 1: Illustration of the microwave dyeing booth developed with the invention.

[0028] Figure 2: Illustration of the flow chart of the continuous dyeing system of narrow sized fabrics developed with the invention in microwave environment.

[0029] Figure 3: Illustration of the temperature distribution in the microwave dyeing booth developed with the invention.

[0030] Element Numbers in Figures

[0031] In order to better explain the dyeing booth developed with the present invention, the parts and elements in the figures are numbered and the equivalent of each number is given below:

[0032] 1. Micro wave antenna

[0033] 2. Micro wave generator

[0034] 3. Rotating rollers

[0035] 4. Narrow fabric separator

[0036] 5. Window

[0037] 6. Narrow fabric outlet

[0038] 7. Water pool

[0039] 8. Narrow fabric inlet

[0040] 9. Glass fan

[0041] 10. Cooling fan

[0042] 11. Motor cylinder

[0043] 12. Generator

[0044] 13. Squeezing cylinder

[0045] 14. Drying drum

[0046] 15. Control panel

[0047] 16. Separator Detailed Description of the Invention

[0048] The invention relates to a dyeing booth for continuous dyeing of narrow fabrics, which is operated by a microwave system to ensure a uniform binding reaction of the dyestuff to the fabric, and to a method of operation of the booth.

[0049] Narrow fabrics can be in different widths between 0.2-30 cm. and can consist of synthetic fibers, natural fibers and their blends. Narrow fabrics are the most widely used fabric group in underwear and outerwear. Examples include stretch ribbons, textile accessory fabrics and tires. The invention, as shown in Figure-1, is a microwave dyeing booth for continuous dyeing of narrow fabrics. The height of the dyeing booth can be between 150 cm and 200 cm. The width of the dyeing booth can be between 100 cm and 150 cm.

[0050] The narrow fabric first enters the microwave dyeing chamber through the narrow fabric inlet (8) shown in Figure- 1. The entry speed of the narrow-sized fabric from the narrow fabric inlet (8) and the exit speed from the narrow fabric outlet (6), which can be adjusted by the motor cylinder (11), and the adjustment of the tension rates in the fabric can be adjusted by means of rotating rollers (3), which can be 10-20 cm in diameter. The distance between the rotating rollers (3), which are positioned both at the top and bottom of the dyeing booth, is 162 cm.

[0051] In the continuous dyeing system of narrow size fabrics, the fabric is firstly impregnated with the dyeing bath solution at a speed of 15-40 m / min. This speed is adjusted and controlled by the motor cylinder (11). The dyeing reaction is carried out at 400-2000 W microwave power depending on the color depth. The dyeing process takes place between 1 minute and 4 minutes depending on the color depth in the dyeing booth with microwave system and at this stage, the temperature of the dyeing booth can be adjusted from the control panel (15) between 60 °C and 140 °C depending on the dyestuff and fabric type. The dyeing process in the dyeing booth is carried out at speeds of 15-40 m / min, which can be controlled and adjusted by the motor cylinder (11). The dyestuff used here is the dyeing bath solution, which contains serial wetting agent, pH buffering agent, equalizer, migration inhibitor, anti-fracture agent and softener.

[0052] The narrow-sized fabric is passed through the squeezing cylinder (13) in such a way that 30%- 100% dye absorption is achieved. In the dyeing booth, there is also a separator-comb system that prevents the dye from mixing with each other while passing at adjustable speeds and tensions determined before the dyeing process. The separator-comb system is made of a material such as Teflon, polypropylene, ceramic which is not affected by the microwave system and does not cause any damage to the system. After the dye impregnation process, the narrow fabric enters the microwave dyeing booth from the narrow fabric inlet (8) and exits the dyeing booth from the narrow fabric outlet (6) at predetermined speeds at a microwave power determined according to the color of the fabric to be dyed for the dyeing reaction, which can be between 400-2000 W, as shown in Figure-1. The passage speed of the narrow fabric through the narrow fabric outlet (6), which can be adjusted and controlled by the motor cylinder (11) from the dyeing booth with microwave system, varies between 2-50 m / min depending on the color depth.

[0053] After the fabric exits the booth, the washing process starts as shown in Figure-2. The narrow fabric outlet (6) is subjected to washing processes according to the type of fabric and dyestuff. After the fabrics pass through the washing process in the continuous system, finishing is applied. The finished fabric is then dried by passing through the drum microwave drying device with a humidity between 6% and 15%. After the washing process, the fabric is finished, dried and finally wrapped. With these steps, dyed and finished narrow sized fabrics are ready for use.

[0054] On the bottom surface of the dyeing booth developed with the present invention, there is also a water pool (7) to ensure the aforementioned humidity range. The 15 cm deep water pool (7) is filled with water during the dyeing process according to the type of fiber and dyestuff.

[0055] The determination of the microwave power, the speed of the narrow fabric exit from the narrow fabric outlet (6) and the speed of the narrow fabric entry from the narrow fabric inlet (8) can be adjusted from the control panel (15). From the control panel (15), the dyeing booth temperature, microwave power level, dyeing booth, automatic interruption of the current when the glass window (5) is opened and closed can be controlled. The parameters of the passage of the narrow size fabric through the dyeing booth can be adjusted according to the type of fabric being dyed and the type of dyestuff used.

[0056] Microwave energy is generated by a magnetron generating high-frequency oscillations in the dyeing booth and the microwave energy is uniformly distributed everywhere by the microwave antenna (1). In the system developed with the invention, there is also a cooling fan (10) that provides cooling of the microwave antenna (1). The microwave generator (2) is at least one or multiple. The distribution of the magnetic field and temperature zones produced by the microwave generator (2) inside the dyeing booth are shown in figure-3. The passage of the narrow fabric through the dyeing booth is regulated from the control panel (15) according to these temperature zones. In the microwave dyeing booth developed with the invention, only the selective heating system for the fabric can be operated by the user from the control panel (15) as on-off operation or intermittent operation without waiting for the dyeing ambient conditions to stabilize.

[0057] For controlling the passage of the narrow fabric through the dyeing booth and in case of emergency intervention, there is also a window (5) with opening and closing function. The window (5), with a height between 70 cm and 80 cm and a width between 55 cm and 65 cm, is covered with a Faraday cage or a coating that forms a transparent surface film (with a Faraday cage effect) to prevent microwave propagation. A Faraday cage is an enclosure made of electrically conductive metal or a mesh of conductors that protects the inner volume from external electric fields. In addition, when the window (5) is opened, the microwave generator

[0058] (2) is automatically closed to prevent microwave emission. The microwave generator (2) is associated with a current cut-off relay. In this way, when the window (5) is opened, the current emitted by the microwave generator (2) is cut off. With this feature, employee safety can be ensured by preventing the dyeing booth from emitting microwaves to the outside.

Claims

CLAIMS1. A dyeing booth for narrow size fabrics; characterized in that it comprises• A microwave antenna (1) for uniform distribution of the microwave energy generated by the microwave generator (2),• At least one microwave generator (2) positioned at the top of the dyeing booth and generating a magnetic field inside the dyeing booth,• Rotating cylinders (3) that enable the tension adjustment of the narrow fabric in the dyeing booth to be adjusted together with the motor cylinder (11),• Squeezing roller (13) that is passed over the narrow fabrics for dye absorption.

2. A dyeing booth according to claim 1 , characterized in that said dyeing booth has a height in the range of 150 cm to 200 cm.

3. A dyeing booth according to claim 1 , characterized in that said dyeing booth has a width in the range of 100 cm to 150 cm.

4. A dyeing booth according to claim 1, characterized in that it comprises a motor cylinder (11) for adjusting the inlet speed of the narrow-sized fabric from the narrow fabric inlet (8) and the outlet speed of the narrow fabric outlet (6).

5. A dyeing booth according to claim 1, characterized in that it comprises rotating rollers (3) having a diameter between 10 cm and 20 cm.

6. A dyeing booth according to claim 5, characterized in that it comprises rotating rollers (3) positioned both at the top and at the bottom of the dyeing booth and spaced 162 cm apart.

7. A dyeing booth according to claim 1, characterized in that it comprises a separatorcomb system which prevents intermixing while passing at adjustable speeds and tensions determined before the dyeing process.

8. A dyeing booth according to claim 8, characterized in that it comprises a separatorcomb system made of a material such as Teflon, polypropylene, ceramic, which is not affected by the microwave system and does not cause any damage to the system.

9. A dyeing booth according to claim 1, characterized in that it comprises a water pool (7) positioned on the bottom surface of the dyeing booth for humidifying the inside of the booth.

10. A dyeing booth according to claim 1, characterized in that it comprises a control panel (15) for determining the microwave power, for user determination of the speed at which the narrow fabric exits the narrow fabric outlet (6) and enters the narrow fabric inlet (8).

11. A dyeing booth according to claim 1, characterized in that it comprises a window (5) for controlling the passage of narrow fabric through the dyeing booth and for emergency intervention.

12. A dyeing booth according to claim 11, characterized in that it comprises a window (5) having a height between 70 cm and 80 cm and a width between 55 cm and 65 cm.

13. A dyeing booth according to claim 11 or 12, characterized in that it comprises a window (5) covered with a Faraday cage or a coating forming a transparent surface film to prevent microwave propagation into the environment in which the dyeing booth is located.

14. A dyeing booth according to claim 11, 12 or 13, characterized in that it comprises a window (5) which, when opened, automatically switches off the microwave generator (2) to prevent microwave emission into the environment of the dyeing booth.

15. A dyeing booth according to claim 1, characterized in that it comprises a cooling fan (10) for cooling the microwave antenna (1) emitting microwave emissions.

16. A dyeing booth according to claim 1, characterized in that it comprises a control panel (15) for controlling the temperature of the dyeing booth, the microwave power level, an automatic interruption of the current when opening and closing the glass window (5).

17. The method of operation of the dyeing booth mentioned in claim 1 characterized in that it comprises the steps;• Determining the speed at which the narrow fabric enters the dyeing booth through the narrow fabric inlet (8) and the speed at which the narrow fabric exits through the narrow fabric outlet (6), by the user on the control panel (15),• Entry of the narrow fabric into the microwave dyeing chamber by the user through the narrow fabric inlet (8),• Adjustment of the tension rate of the narrow fabric by the user by means of the rotating rollers (3),• Dye impregnation of narrow fabrics,• Determination of dyeing booth temperature from the control panel (15) according to dyestuff and fabric type,• Passing the narrow fabric through the squeezing roller (13) in such a way that the dye is absorbed,• Exit of the narrow fabric from the fabric outlet (6) of the microwave dyeing booth.

18. The method of operation of the dyeing booth according to claim 17, characterized in that in the process step of dye impregnation of narrow fabrics, the dye impregnation process is carried out at a speed of 15-40 m / min.

19. The method of operation of the dyeing booth according to claim 17, characterized in that, in the process step of dye impregnation of narrow fabrics, the dye impregnation process is carried out at a microwave power of 400-2000 W.

20. The method of operation of the dyeing booth according to claim 17, characterized in that, in the process step of dye impregnation of narrow fabrics, the dye impregnation process is carried out between 1 and 4 minutes.

21. The method of operation of the dyeing booth according to claim 17, characterized in that in the process step of determining the temperature of the dyeing booth from the control panel (15) according to the dyestuff and fabric type, the booth temperature is between 60 °C and 140 °C.

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