Dyeing machine reducing water consumption

Abstract

The present invention describes a dyeing machine (a) that supports sustainable production practices by optimizing the use of water and chemicals during dyeing processes. The design of the dyeing machine (a) ensures maximum recycling and reuse of water, thus reducing environmental impacts and lowering operating costs. The machine offers a more environmentally friendly approach as it reduces energy and water consumption while using the dye solution efficiently.

Description

[0001] Dyeing Machine Reducing Water Consumption

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a machine for the application of chemicals to fabrics in the textile industry, which reduces the use of water.

[0004] PRIOR ART

[0005] Textile products are dyed and colored in fabric dyeing machines using water and chemicals. Fabric dyeing machines are also called jet dyeing machines. These machines vary depending on the properties of the material to be dyed. In fabric dyeing machines, the fabric conveyed from the nozzle comes to the J-box - the area where the fabric coming from the nozzle is dyed, stored and preserved. Here, the sorted fabric is circulated and dyed until the desired properties are achieved.

[0006] The J-box used in the state of the art is known. Their width varies depending on the J- box capacity. Because of these high values, a lot of chemicals and water are used. Chemical materials and dyes used in large quantities cause environmental pollution. Water consumption can cause great harm in the long term in terms of both financial and natural water resource conservation.

[0007] Nowadays, in the machines used for dyeing on textile products made of cotton, viscose, synthetic and their mixture materials, the fabric given to the system is exposed to water and chemicals in the pools, then it is dyed by coming out of the assemblies and this process is cycled and the dyeing process is carried out. The most important issue while performing these processes is the flotte ratio. It is the ratio of 1 kg of fabric to the waterchemical solution used for dyeing. With existing machines, approximately 45-60 litres of water are consumed to dye 1 kg of fabric. This consumption is reflected in the factory due to the amount of water and chemicals used. High amounts of chemical use cause environmental pollution and waste of natural resources.

[0008] As a result, all abovementioned problems have made it necessary to make an improvement in the relevant technical field. OBJECT OF THE INVENTION

[0009] The present invention aims to eliminate the abovementioned problems and to make a development in the relevant technical field.

[0010] The main object of the present invention is to reduce the amount of water used during dyeing of textile products.

[0011] Another object of the present invention is to save energy and costs by ensuring minimum water consumption.

[0012] Another object of the present invention is to reduce environmental pollution by reducing wastewater formation.

[0013] The structural features and advantages of the invention will be understood more clearly thanks to the figures and claims given below.

[0014] BRIEF DESCRIPTION OF THE INVENTION

[0015] In order to achieve all the purposes mentioned above and which will emerge from the detailed description below, the present invention is a dyeing machine comprising: a tank for dyeing fabric in the textile industry, cover that provides fabric inlet and outlet connected to the tank, an inlet reel comprising an idler cylinder and positioned inside the tower to guide the fabric, transition pipe that allows the fabric that is entered into the tank to reach the inlet reel, nozzle that is structured as a chamber where the fabric coming from the inlet reel meets the flotte solution, j-box positioned inside the tank to support the penetration of the flotte solution into the fabric, with holes underneath configured to prevent the fabric from passing through while allowing the liquids to pass through, collection panel that allows the water passing through the holes at the bottom of the j- box to accumulate and reach the collector, and the transmission pipe that transmits the fabric to the j-box, a cover positioned on the tank that allows the fabric to enter and exit the machine. Accordingly, the present invention comprises the following; a boat positioned under the nozzle and used as a reservoir in which the flotte solution in contact with the fabric is collected, a separation cylinder that is positioned inside the boat and allows the fabric that has come into contact with the flotte solution to move upwards, thus separating the fabric from the aqueous solution with which it moves, a drive reel with drive cylinder inside, positioned in a tower above the tank to allow the fabric, which is directed upwards and separated from the aqueous solution, to enter the tank, an end pipe with one end connected to the j-box and the other end connected to the drive reel so that the fabric directed from the drive reel towards the tank enters the j-box, a discharge pipe positioned on the underside of the boat adjacent to the boat, with one end connected to the boat and the other end connected to the collection panel, so as to ensure that the solution collected in the boat and separated from the fabric is transferred to the flotte transfer assembly configured to ensure that the solution is returned to the nozzle, at least one pump to support the flotte solution in the flotte transfer assembly to reach the nozzle.

[0016] A preferred embodiment of the invention is that the said tank has a cylindrical structure to increase its pressure resistance.

[0017] In another preferred embodiment of the invention, the said cover is made of a transparent material that allows the inside of the tank to be seen.

[0018] In another preferred embodiment of the invention, said cover comprises a window made of a composite material to provide pressure resistance.

[0019] In another preferred embodiment of the invention, said pump is one of the individuals or combinations selected from the group comprising a centrifugal pump, gear pump, screw pump, vane pump, peristaltic pump, piston pump, lobe pump.

[0020] A preferred embodiment of the invention comprises an operator stand associated with the tank in order to enable maintenance, repair and control of the machine components located in the upper part of the tank.

[0021] An alternative embodiment of the invention comprises at least 4 cylinders, at least one of which is a separation cylinder and at least one of which is a drive cylinder.

[0022] The protection scope of the invention is specified in the claims and cannot be limited to the description made for illustrative purposes in this brief and detailed description. It is clear that a person skilled in the art can present similar embodiments in the light of the above descriptions without departing from the main theme of the invention.

[0023] BRIEF DESCRIPTION OF DRAWINGS

[0024] The sectional view of the dyeing machine is given in Figure 1 .

[0025] Figure 2 shows the perspective view of the rear portion of the dyeing machine. The drawings are not intended to limit the scope of protection defined in the claims and should not be referred to in isolation without reference to the technical description in the description of the present invention for the purpose of interpreting the scope defined in those claims. The drawings in question are intended to define the invention with clarity.

[0026] DESCRIPTION OF THE REFERENCE NUMBERS IN FIGURES a. dyeing machine b. tank

[0027] 1. Inlet reel

[0028] 2. Nozzle

[0029] 3. Separation cylinder

[0030] 4. Drive reel

[0031] 5. J-box

[0032] 6. Pump

[0033] 7. Collector

[0034] 8. Discharge pipe

[0035] 9. Transition pipe

[0036] 10. Boat

[0037] 1 1 .Tower

[0038] 12. End pipe

[0039] 13. Cover

[0040] 14. Operator stand

[0041] 15. Flotte transfer assembly

[0042] 16. Collection panel

[0043] DETAILED DESCRIPTION OF THE INVENTION

[0044] In this detailed description, the inventive subject DYEING MACHINE REDUCING WATER CONSUMPTION is described by means of examples only for clarifying the subject matter such that no limiting effect is created.

[0045] This machine optimizes the use of water and chemicals during dyeing processes, thus supporting sustainable production practices. The design of the machine allows maximum reduction of water used, which reduces both environmental impact and operating costs. Efficient use of water ensures efficient use of the flotte solution, that is, the dye solution for the dyeing machine (a). Dye solution is a mixture of dye and water. Alternative areas of use of the invention may also involve processes such as washing, pre-treatment and post-treatment. With the use of appropriately optimized chemicals and fabrics, operations that conventional jets can perform can be performed more efficiently.

[0046] The sectional view of the dyeing machine (a) is given in Figure 1 , and the perspective view of the rear portion is given in Figure 2. Accordingly, the present invention comprises the following: a tank (b), a cover (13) connected to the tank (b), a tower positioned on the tank (1 1 ), an inlet reel (1 ) positioned inside the tower (11 ), transition pipe (9) with one end connected to the inlet reel (1 ), nozzle (2) that is configured as a chamber where the fabric coming from the inlet reel (1 ) meets the flotte solution, j-box (5) positioned inside the tank (b) and having holes structured at the bottom to prevent the fabric from passing while ensuring the passage of liquids, collection panel (16) that allows the water passing through the holes at the bottom of the j-box to accumulate and reach the collector (7), cover (12) positioned on the tank (b) which allows the fabric to enter and exit the machine, boat (10) positioned under the nozzle (2), separation cylinder (3) positioned inside the boat (10), drive cylinder with drive reel (4), end pipe (12) with one end attached to the j-box and the other end attached to the drive reel (4), a discharge drain pipe (8) positioned on the underside of the boat (10) adjacent to the boat (10), with one end connected to the boat (10) and the other end connected to the collection panel (16), so that the solution accumulated in the boat (10) and separated from the fabric is transferred to the flotte transfer installation (15) configured to ensure that the solution is brought back to the nozzle, a pump (6) to support the flotte solution in the flotte transfer assembly (15) to reach the nozzle (2). Explanations regarding the elements that are essential for the operation of the invention are given below.

[0047] The preferred embodiment of the invention comprises a tank (b) to ensure that the elements to be mentioned below are associated with each other and to determine the environment in which the process will be carried out. In the preferred embodiment of the invention, the tank (b) is structured cylindrically in order to withstand the high pressure generated.

[0048] The cover (13) positioned on the tank (b) allows the fabric to be processed (dyed for the present invention) to enter the system. In the preferred embodiment of the invention, the cover (13) comprises a transparent window that allows the inside of the tank (b) to be seen. Said window is made of a composite material to provide pressure resistance. When the fabric enters the tank (b), it moves into the transition pipe (9) and enters the circulation system through the transition pipe (9). The transition pipe (9) is used to determine the direction of the fabric and to ensure that the fabric advances in the tank (b) in a controlled manner.

[0049] The fabric that moves on the transition pipe (9) comes to the structure called tower (1 1 ) positioned on the tank (b). There is an inlet reel (1 ) inside the tower (1 1 ). This structure is named as the inlet reel (1 ) in the invention because it is the first reel that the fabric entering the tank (b) encounters. The inlet reel (1 ) comprises an idler cylinder and ensures that the tension of the fabric is controlled. Thanks to the idle, i.e. free rotating cylinder inside the inlet reel (1 ), the fabric is guided with a controlled tension while the speed is controlled and all factors determining the speed of the fabric are directly related to the homogeneous realization of the process to be carried out on the fabric. If the speed is higher or lower than necessary, morphological errors or abrage may occur on the fabric.

[0050] The fabric comes to nozzle (2) after the inlet reel (1 ). The nozzle (2) is the structure that provides the first contact of the fabric with the dyeing solution. The nozzle (2) ensures that the solution penetrates the fabric evenly during the dyeing process and that the dye spreads effectively between the fabric fibers, allowing the colors to appear vivid and even. In the nozzle (2), the solution with the determined flotte ratio is applied to the fabric and the chemical application phase takes place in the nozzle.

[0051] In the invention, there is a boat (10) positioned under the nozzle (2). Boat (10) is the reservoir where the flotte solution is collected. The boat (10) comprises a separation cylinder (3) used to change the direction of the fabric coming from the inlet reel (1 ) and passing through the nozzle (2). The separation cylinder (3) is an idler cylinder and ensures that the solution is purified from the fabric after it passes through the nozzle (2) area. It does this by providing a movement that includes a movement vector in the upward direction of the fabric. In other words, the fabric must move in a way that creates work against gravity because the separation process depends on the solution not being able to rise to the top due to gravity. In addition, if we consider that the fabric is in a certain tension due to the tension originating from the reel system in which the separation cylinder (3) is located, if the fabric delivered to the separation cylinder (3) does not come into contact with the flotte solution accumulated in the boat (10), it should be assumed that the separation cylinder (3) also performs the squeezing process. The separation of the solution (and therefore water) from the fabric due to this squeezing process provides an additional separation to the separation caused by gravity.

[0052] After passing through the separation cylinder (3), the fabric must be allowed to enter the tank (b) and the fabric must enter the j-box (5) inside the tank (b) from above. J-box (5) is positioned with a gap at the top for the fabric to enter. In other words, the fabric that moves upwards and is largely free from chemical solutions must be directed downwards. The present invention comprises a drive reel (4) positioned above the tank (b) and higher than the separation cylinder (3) and comprising a drive cylinder in order to direct the fabric passing through the separation cylinder (3) into the J-box. The drive cylinder supports the movement of the fabric within the dyeing machine (a) by means of a motion drive element that enables the cylinder to rotate with external energy. It is important that the preferred drive reel (4) of the invention is higher than the separation cylinder (3), otherwise the fabric cannot move upwards after passing through the separation cylinder (3) and the separation process, which constitutes the technical benefit of the invention, cannot be achieved with the desired efficiency.

[0053] This process of the drive reel (4) that directs the fabric into the j-box (5) is guided by an end tube (12) associated with the drive reel (4) at one end and the j-box (5) at the other. The end pipe (12) is named in this way due to the end of the movement of the fabric on the cylinders.

[0054] The j-box (5) located in the tank (b) is positioned to direct the fabric within the tank (b) to ensure that the dye is fully integrated with the fabric fibers, thus ensuring color consistency during the dyeing process. J-box (5) is a structure positioned inside the tank (B) to support the penetration of the flotte into the fabric and has perforated holes on the bottom and / or side that are configured to prevent the fabric from passing while ensuring the passage of liquids. Its internal structure is designed to avoid friction or knotting. Teflon is used in the preferred embodiment of the invention. Teflon is also used in conventional machines, but since the fabric mentioned within the scope of invention protection is highly purified from liquid, it should have a more slippery surface and Teflon meets the expectation in the preferred embodiment.

[0055] The fabric passing through the J-box (5) transfers some more of the solution on it to the collection panel (16) thanks to the perforated holes on the J-box (5). This is also the case in the conventional system, but since the machines in the prior art do not have a liquid removal system as in the invention that is intended to be protected, much higher amounts of liquid enter the j-box (5) together with the fabric and therefore much higher amounts of solution have to be collected. These solutions cannot be collected when there is a blockage in the perforated holes for various reasons. The fabric passing through the J-box (5) comes back to the transition pipe (9) and the circulation of the fabric is ensured. Chemical solutions that cannot be collected due to blockages in the holes also enter the circulation together with the fabric. This situation is undesirable and affects the dyeing performance of the fabric, and may cause undesirable results in efficiency and speed, and therefore in energy usage. In any embodiment of the invention that is sought to be protected, since there is no solution input into the j-box (5) together with the fabric as in the machines in the prior art of the invention, the collection has no effect on performance and a constant efficiency can be achieved. This situation creates a safer environment by preventing accidents that may occur due to blockages.

[0056] During the circulation of the fabric, while the fabric continues to the separation cylinder (3), the solution collected in the boat (10) is transmitted to the collector (7) with the help of a discharge pipe (8) configured under the boat (10) with one end connected to the boat (10) and the other end to the collection panel (16). In this way, both the solution separated before the fabric enters the j-box (5) and the solution coming from the perforations in the j-box (5) are collected in the collection panel (16) and then in the collector (7). The discharge pipe (8) is the most important element of the invention that enables the fabric to be separated from the solution, which is the most important technical benefit of the invention. The connection of the discharge pipe (8) to the collection panel (16) ensures that the temperature of the treatment carried out on the fabric remains optimized. The discharge pipe (8) provides a transmission by passing through the tank (b) and maintaining the temperature in the liquid at the temperature required for the process. As a result of the discharge pipe (8) being directly connected to the collector (7), problems with temperature occur.

[0057] In an alternative embodiment of the invention, the boat (10) and the discharge pipe (8) are one piece. A monolithic structure prevents negative situations that may occur as a result of repeatedly disassembling and assembling separately associated structures for reasons such as maintenance or repair.

[0058] The solution collected in the collector (7) also needs to be circulated. For this reason, there is a flotte transfer assembly (15) with one end associated with the collector (7) and the other end associated with the nozzle (2). Thanks to the flotte transfer assembly (15), a large part of the flotte solution is circulated through the nozzle (2), boat (10), discharge pipe (8), collection panel (16), collector (7), flotte transfer assembly (15), while the remaining part of the solution that helps the dyeing of the fabric is circulated through the nozzle (2), j-box (5), collection panel (16), collector (7), flotte transfer assembly (15). However, since the amount of solution entering the j-box is reduced at very high rates, the amount of solution circulating in the J-box route is low. Only as much solution as the fabric can take enters the J-box. This amount of water entering the fabric varies depending on its absorbency and type.

[0059] The preferred embodiment of the invention comprises at least one pump (6) associated with the flotte transfer assembly (15) in order to ensure the circulation of the solution. The pump (6) ensures the transfer of the solution planned to be in contact with the fabric again from the collector (7) which is lower than the other to the nozzle (2) which is higher. In the preferred embodiment of the invention, individuals or combinations selected from the group consisting of centrifugal pump (6), gear pump (6), screw pump (6), vane pump (6), peristaltic pump (6), piston pump (6), lobe pump (6) are used.

[0060] Based on what has been explained above, the invention performs the separation process with 3 cylinders. An alternative embodiment of the invention comprises at least 4 cylinders, and at least one of the cylinders is configured as a separation cylinder (3) and at least one is configured as a drive cylinder.

[0061] In an alternative embodiment of the invention, there is at least one squeezing system before and / or after the separation cylinder (3) to ensure the removal of the liquid after the application of the solution to the fabric between the nozzle (2) and the drive reel (4). The squeezing system is configured to support a high removal of the solution or liquid from the fabric of technical interest of the separation cylinder (3) and to ensure that the removed solution or liquid reaches the flotte transfer assembly (15) in such a way as to ensure that the removed solution or liquid is returned to the level (2), without creating an environment that prevents the reuse of the solution or liquid.

[0062] The preferred embodiment of the invention comprises an operator stand (14) associated with the tank (b) in order to ensure maintenance, repair and control of the machine components located in the upper part of the tank (b). The basic working principle of the dyeing machine (a) mentioned within the scope of the invention is based on reducing both environmental impact and operating costs by maximizing the reuse of water and dyestuff. The design of the machine ensures that it operates efficiently in a continuous cycle, ensuring that water and dye are effectively recovered with each use. In addition, reducing the amount of water used means that the amount of liquid that needs to be heated in the heating process is reduced, which means that higher temperatures can be reached with the same amount of heat, reducing energy use. The most important factors in sustainable practices in the textile industry are water and energy use and recycling, which are made efficient in reducing environmental impact.

[0063] The protection scope of the invention is specified in the appended claims and cannot be limited to the description made for illustrative purposes in this detailed description. Likewise, it is clear that a person skilled in the art can present similar embodiments in the light of the above descriptions without departing from the main theme of the invention.

Claims

CLAIMS1. Dyeing machine (a) which is used to dye fabric in the textile industry, comprising;• A tank (b),• Cover (13) that provides the fabric inlet and outlet connected to the tank (b),• Inlet reel (1 ) comprising an idler cylinder and positioned inside the tower (11 ) to ensure the guidance of the fabric,• Transition pipe (9) that allows the fabric that is entered into the tank (b) to reach the inlet reel (1 ),• Nozzle (2) configured as a chamber where the fabric coming from the inlet reel (1 ) meets the flotte solution,• J-box (5), which is positioned inside the tank (B) to support the penetration of the liquor into the fabric and has holes structured at the bottom to prevent the fabric from passing while ensuring the passage of liquids,• Collection panel (16) that allows the water passing through the holes at the bottom of the J-Box to accumulate and reach the collector (7).• Transition pipe (9) that transmits the fabric to the J-box (5),• Cover (12) which allows the fabric to enter and exit the machine and is positioned on the tank (b), characterized by comprising;• A boat (10) positioned under the nozzle (2) and used as a reservoir in which the flotte solution in contact with the fabric is collected,• A separation cylinder (3) that is positioned inside the boat (10) and allows the fabric that has come into contact with the flotte solution to move upwards, thus separating the fabric from the aqueous solution with which it moves,• A drive reel (4) with drive cylinder inside, positioned in a tower (1 1 ) above the tank (b) to allow the fabric, which is directed upwards and separated from the aqueous solution, to enter the tank,• An end pipe (12) with one end connected to the j-box (5) and the other end connected to the drive reel (4) so that the fabric directed from the drive reel (4) towards the tank enters the j-box (5),• A discharge pipe (8) positioned on the underside of the boat (10) adjacent to the boat (10), with one end connected to the boat (10) and the other endconnected to the collection panel (16), so as to ensure that the solution collected in the boat (10) and separated from the fabric is transferred to the flotte transfer assembly (15) configured to ensure that the solution is returned to the nozzle (2),• At least one pump (6) to support the flotte solution in the flotte transfer assembly (15) to reach the nozzle (2).

2. A dyeing machine (a) according to claim 1 , characterized in that; said tank (b) has a cylindrical structure to increase the compressive strength.

3. A dyeing machine (a) according to claim 1 , characterized in that; said cover (13) is made of a transparent material so that the inside of the tank (b) can be seen.

4. A dyeing machine (A) according to claim 1 or 2, characterized in that; said cover (13) comprises a window made of a composite material to withstand pressure.

5. A dyeing machine (a) according to claim 1 , characterized in that; said boat (10) and discharge pipe (8) are monolithic.

6. A dyeing machine (A) according to claim 1 , characterized in that; said pump (6) is selected from the group consisting of centrifugal pump (6), gear pump (6), screw pump (6), vane pump (6), peristaltic pump (6), piston pump (6), lobe pump (6).

7. A dyeing machine (A) according to claim 1 , characterized in that; the tank (b) comprises an operator's stand (14) associated with the tank (b) to enable maintenance, repair and control of the machine components located at the top.

8. A dyeing machine (A) according to claim 1 , characterized in that it comprises at least one squeezing system between the nozzle (2) and the drive reel (4), before and / or after the separation cylinder (3) to support the removal of the liquid after the application of the solution to the fabric.

9. A dyeing machine (a) according to any one of the preceding claims, characterized in that; it comprises at least 4 rollers, at least one of which is a separation cylinder (3) and at least one of which is a drive roller.

Images