TUKEK, Rafet (Atatürk Sanayi Bölgesi Ürgüplü Cad. No:1, Hadimköy, Istanbul, 34555, TR)
CLAIMS
1- In order to be able to apply on furniture stuff used in furniture sector, fabrics in clothing sector and curtain fabrics and besides manufacture product with this process in sectors of packaging, wallboard; the cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process characterized by the main procedure stages as;
• providing pattern transfer by passing the fabric (4) going out wetly from flocking unit (1) through cold and wet embossing unit (2) consisting of steel cylinder with pattern (5), flat cylinder (6) transferring the pattern directly to the fabric, • drying the patterned (pattern transferred on which) wet fabric with flock (3),
• single color or multi-color embossing of the fabric flocked and on which pattern has been transferred or dyeing it in rope dyeing machines, and applying the procedure stages immediately after flat flocking procedures as sequential. 2- Cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process, in order to be able to apply on furniture stuff used in furniture sector, fabrics in clothing sector and curtain fabrics and to manufacture product with this process in sectors of packaging and wallboard characterized in the main process stages as follows: • transfer of pattern on the wet fabric (4) formerly colored flocked in the flocking unit and directly passed through the patterned steel cylinder (5) and the flat cylinder (6) in the embossing unit (1) (cold and wet embossing unit (2)),
• washing and drying the patterned and dried fabric in the washing machines, and sequential application of these stages immediately after flat flocking process. 3- The apparatus for cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process as claimed in Claims 1 or 2 and characterized in that the cold and wet embossing unit comprises steel cylinder with pattern (5) flat cylinder (6) and drive motors (14), and safety cylinders (15) as the main elements. 4- The cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process as claimed in any of the preceding claims and characterized by dyeing the fabric patterned and dried at flocking line in dyeing machines. 5- The cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process as claimed in any of the preceding claims and characterized by dyeing the fabric patterned and dried at flocking line as single color in textile printing machines.
6- The cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process as claimed in any of the preceding claims and characterized by dyeing the fabric patterned and dried at flocking line as multi-color in textile printing machines.
7- The cold embossing process for pattern transfer over flocked wet fabric and the fabric manufactured according to this process as claimed in any of the preceding claims and characterized by dyeing the fabric patterned and dried by covering over it with flock with pattern or flat flock.
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COLD-EMBOSSING PROCESS FOR PATTERN TRANSFER OVER FLOCKED WET FABRIC AND THE FABRIC MANUFACTURED ACCORDING TO TIDS
PROCESS
FIELD OF THE INVENTION
This invention is related with the process of direct pattern transfer through cylinders onto wet and flocked base before drying the fabric flocked at the flocked base production line in the furnace for the furniture stuff used in furniture sector, fabrics in clothing sector and products in curtain manufacturing, packaging or wallboard production sectors and the fabrics manufactured according to this process.
PRIOR ART
In the known technique, the pattern obtained by pressing the heated steel cylinder with pattern with pressure over the dried fabric base by flocking. The process applied according to this technique is applied with the machines named hot emboss. The process in which the known technique is applied has been shown in Figure 3.
As it is shown in Figure 3, embossing over flocked fabric in the hot emboss method applied according to the known technique is applied when the flocked fabric is dry (without being wet). The most important disadvantage of hot embossing method is that the general appearance of final product is unsightly and not permanent. The appearance on which emboss is made and the colors lose their appearances after a short time and the quality is deformed. The pattern transferred with hot embossing made over the flocked fabric is not seen clearly. After a short time of using the fabric, the colors and pattern are deformed. Because, the pattern is transferred over the flocked and dried fabric and depending on this, the pattern cannot penetrate to the base of the flocked fabric and the adhesive in the base of it.
In the document with publication number WO 01/21878 Al the application of which has been made on 21 September 2000 and that has been published on 29 March 2001, another process has been explained. The process explained in the document number WO 01/21878 Al is the process of air embossing. In this process, the flocked wet fabric is blown pressurized air onto fabric in screen cylinder by passing it from cavities with patterns over screen cylinder. The surface of the screen cylinder used in this invention explained with this publication has cavities and full parts that shall form pattern and through which air passes. It passes from the cavity parts of the pressurized air cylinder and applies pressure over flocked wet fabric and forms pattern. The edge parts of the pattern
transferred over flocked fabric with the method explained in the publication number WO 01/21878 Al are not net (sharp). The pattern has a rough appearance. Because, the pattern is transferred over the flocked wet fabric with air and depending on this, it is obtained by lying of flocks to right and left and the flocks are not dipped in the adhesive plastered on the cloth by steel cylinder as in the process developed with this invention. Consequently, both products are totally different from each other (the product manufactured with the process developed with this invention and the product manufactured with another process in the document publication number WO 01/21878 Al).
In the method explained in publication number US 2003/097943 that has been published on 29 May 2003, applied according to the known technique and the application of which has been made on 11 February 2002, it has been explained that the simultaneous patterning of the dye emboss and flock application for the fabric is being made as synchronicity. In this publication, the process of flocking with pattern after some parts of the pattern chosen simultaneously are being made dye emboss over the fabric and re- patterning it after passing between the cylinders are explained. In this process, the preliminary processing unit is explained in order to give base color to the fabric. In the preliminary processing, it has been aimed that the pores on the surface of the fabric are covered with chemical substances and thus in later phases the transfer of pattern to the surface is becoming more efficiently and the probable stains are prevented. After preliminary processing unit, the fabric is dried prior to embossing. In this step, the drier fixes the base-coating, base color and pores realized in preliminary processing unit. After the fabric goes out from the drier, it enters into hot embossing unit built from two cylinders which are opposite each other. Thus, the hot fabric is applied pressure. In this step, the hot fabric is flattened and the wrinkles are removed. The faults prior to embossing are eliminated. After this step, the fabric is cooled by passing it between the cylinders that are opposite each other and between which cold water is passed at 5 0 C to 10 0 C. After this step, the fabric comes to dye embossing and flock adhesive giving unites. It is given dye embossing and flock adhesive with synchronal pattern with the method known. Later on, the fabric enters into flocking unit and only the parts to which flock adhesive is applied are being flocked. The other parts on the fabric stay as multi-color dye embossed. Depending on the desire, the flocked fabric on which pressure is applied is passed between the cylinders with relief on and counter cylinder. In this phase, the pattern is transferred over the flocked areas with flock as patterned only through cylinders. At the end of this phase, the fabric is dried and cooled. In the process explained in this publication, over the fabric is
applied multi-color dye embossing and this embossing is applied synchronic or patterned flock in suitable state. Later, depending on the desire, relief pattern embossing is applied. At end of this step the fabric is dried and cooled. In the product manufactured with this process developed by this invention, the surface of the fabric is totally covered with flock. In the invention explained in the publication number US 2003/097943, the base fabric surface is covered partially with dye and partially with flock with pattern and it is very different from the product manufactured with this process developed by this invention and totally a different product.
In the publication number GB 2 066 105 published on 08 July 1981, the application of embossing over the fabric has been explained. In this publication, the production of fabric under which there is foam coating has been explained. In the said document, wet foam is covered with flock and dried. After that, it is given pattern by applying pressure to foam coating. The pressure of 8 tons is applied over the dried fabric. This method is similar to the known hot embossing method. The process and product defined in this publication do not resemble at all to the process developed with this invention and the product manufactured according to this process. The process developed with this invention is consisting of transferring the pattern over the steel cylinder onto flat flocked colorless wet base with flock and dyeing it in dye machines and dye embossing machines.
In patent study, some patent publications relating to emboss over paper have been determined. These are;
• JP 2000-73299 A (publication date 07.03.2000),
• JP 2004-183163 A (publication date 02.07.2004),
• DE 2051716 A (publication date 08.06.1972),
• GB 2270931 A (publication date 30.03.1994), • EP 0687771 A2 (publication date 20.12.1995),
• JP 11 -8177 A (publication date 26.03.1999),
All these publications are related with embossing over paper, not related with fabric flocked. Besides, none of these publications tells about steel cylinder. Therefore, the processes explained in these publications are different from the process developed with this innovation in terms of both application fields and application forms.
THE PURPOSES FOR WHICH THE INVENTION IS DEVELOPED
The following have been aimed in developing cold embossing process for pattern transfer over wet fabric flocked through this invention and the fabric manufactured according to this process: • Providing pattern transfer without needing heating procedure in steel cylinder applied in hot embossing process,
• Providing pattern transfer without needing heating procedure in high pressure ambient applied in hot embossing process,
• Applying cold and wet embossing process instead of hot embossing process, • Removing preliminary drying procedure in hot embossing process and in this way not needing any preliminary drying process,
• Completion rapidly of all stages of the process as sequential,
• Providing lower machinery investment cost in comparison to hot embossing and air embossing processes, • Providing lower energy cost in comparison to hot embossing process,
• Increasing new product improvement opportunities more easily with less cost,
• Providing operational ease,
• Providing high productivity,
• Improving the appearances and permanence of the effects on patterns The most important advantages of cold embossing process for pattern transfer over wet flocked fabric developed with this technique and the fabric manufactured according to this process in comparison to the known technique may be listed as follows;
• Providing direct pattern transfer over the fabric (not dyed-not colorized) going out wetly form flocking unit instead of dried fabric base by being flocked, • Removal of heating procedure on steel cylinder applied in hot embossing process,
• Removal of high pressure ambient applied in hot embossing process,
• Removal of air applied in air embossing process,
• Making direct pattern transfer from flocking unit over the fabric going out wetly without any preliminary drying process and applying the process (the stages as sequential) uninterruptedly,
• Obtaining light and dark colors in embossing and dyeing processes as the flocks pressed by the steel cylinder are dipped in the adhesive subjacent in order to give support,
• Providing net and permanent patterns on fabric flocked.
In order to be able to explain cold embossing process for pattern transfer over flocked wet fabric developed with this invention and the fabric manufactured according to this process, the figures prepared and presented in the annex are consisting of the following:
Figure 1 - Process developed with this process
Figure 2 - Cutaway view of cold and wet embossing unit
Figure 3 - Process applied according to the known technique In order to be able to explain cold embossing process for pattern transfer over flocked wet fabric developed with this invention and the fabric manufactured according to this process, the parts (elements) in the figures prepared and presented in the annex have been given number separately. And the explanation of each part (element) which is given numbers has been stated as follows: 1- Flocking unit
2- Wet embossing unit
3- Drying Unit (Furnace)
4- Flat flocked wet fabric
5- Cylinder with pattern 6- Flat cylinder
7- Wet fabric on which pattern transfer has been made with wet embossing method
8- Flat ground with flock manufactured at flocking line
9- J-box
10- Dust removing unit
11- Hot and pressed steel cylinder with pattern
12- Cooling cylinders,
13- Fabric on which pattern has been given with hot embossing, 14- Drive motors 15- Safety cylinders
DETAILED EXPLANATION OF THE INVENTION
Before detailed explanation of cold embossing process for pattern transfer over flocked wet fabric developed with this invention and the fabric developed according to this process, it is necessary to consider the hot embossing process applied according to the known technique for pattern transfer in fabrics with flock at length.
In hot embossing process for pattern transfer in fabrics with flock;
• The wet fabric having flat base flocked is dried,
• It is passed from J-box (9) unit (J-box unit provides the goods to be accumulated uninterruptedly until the new product is loaded to conveyer sheet iron by taking 30 meter product inside.)
• The dried fabric (8) having flocked flat base passed from J-box unit (9) is passed from dust removing unit (10),
• The dried fabric (8) having flocked flat base passed from dust removing unit (10) is pressed by hot cylinder with pattern (11) and the pattern transfer is realized,
• As the flocked fabric for which pattern transfer has been made is hot, it is cooled (12), And in this way the fabric to which pattern has been given is obtained (13).
The main procedures' stages of cold embossing process for pattern transfers over flocked wet fabric developed with this invention are; • Providing pattern transfer by passing the fabric (4) going out wetly from flocking unit (1) through directly the cylinder with pattern (5) and flat cylinder (6) (through cold and wet embossing unit (2)),
• Drying patterned flocked wet fabric (3)
• Dyeing the flocked and patterned fabric with flock with single color or multi-color embossing method or dyeing them in rope dyeing machines.
The most important characteristic of cold embossing process for pattern transfer over flocked wet fabric developed with this invention is that the direct pattern transfer is made over the fabric (4) flocked but not dyed that has gone out wetly from flocking unit of process stages and they are dried and dyed later and these process stages are realized as sequential.
The main elements of cold or wet embossing unit (2) in cold embossing process for pattern transfer over flocked wet fabric developed with this invention are consisting of steel cylinder with pattern (5) and flat cylinder (6), drive motors (14) and safety cylinders (15). The steel cylinder with pattern (5) is preferentially the patterned steel cylinder with pattern on which the fabric is to be embossed. The flat cylinder (6) is the cylinder the surface of which is flat and preferentially made of rubber and steel. The drive motors (14) is giving movement to the cylinders, the safety cylinders (15) provide the passing of the fabric on which the pattern is to be transferred to be neat from the cylinders (5 and 6) and prevent the fabric from sliding.
The pattern transfer of all kinds of forms and appearances is realized over the fabrics by applying cold embossing process for pattern transfer over flocked wet fabric developed with this invention. After the fabric manufactured according to cold embossing process for pattern transfer over flocked wet fabric developed with this invention goes out as patterned at the flocking line and dried, it is. dyed in dyeing machines.
The fabric going out as patterned and dried at flocking line is dyed as single color or multi-color in textile embossing machines. After the fabric manufactured according to cold embossing process for pattern transfer over flocked wet fabric developed with this invention goes out at flocking line as patterned and dried, the product is covered with flock and dyed.
Another application of cold embossing process for pattern transfer over flocked wet fabric comprises the following stages: • transfer of pattern on the wet fabric (4) formerly colored flocked in the flocking unit (1) and directly passed through the patterned cylinder (5) and the flat cylinder (6) in the embossing unit (1) (cold and wet embossing unit (2)),
• Washing and drying the patterned and dried flocked fabric in the washing machines,
Dying process is not required in this application.
The cold embossing process for pattern transfer over flocked wet fabric developed with this invention is used in pattern transfer to furniture stuff and clothing fabrics used in furniture and clothing sectors. Besides, the products may be manufactured with this process in the sectors of curtain, packaging and wallboard.
THE ADVANTAGES OF INVENTION
The cold embossing process for pattern transfer over flocked wet fabric developed with this invention and the fabric manufactured according to this process have the following advantages:
Differing from all other products, the flocks sunk into the adhesive over the cloth by the steel cylinder concordant to its pattern in the product after embossing and dyeing,
• The pattern layers netter and more beautiful, • The pattern is permanent and not deformed,
• As the free flocks and flocks sunk into adhesive shall absorb different dye at dyeing stage, surtone colors are formed.
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