The Field of the Invention

Invention relates to indigo warp dyeing machine developed for solution of issue of dyeing agent remaining in more quantity in mid and side parts of fabric defined as right-left difference or wing difference arising from cavity occurring in squeezing roller in Slasher warp dyeing machines due to failure to provide squeezing function equally as a result of less squeezing roller sides.

Background of the Invention

Denim fabrics having an essential place in textile market go under several treatments from production stage to end stage of delivery to consumer as cloth. Dyeing is the application of dye or pigments onto textile materials such as fibres, yarns and fabrics in order to achieve desired colour with the colour fastness by means of physical or chemical actions. Dyeing methods applied for textiles are diversified and dyeing can be made in 5 production stages in 2 differing ways and thus different colour, style and textures can be provided to products. Rope dyeing technique is the oldest method used in indigo dyeing. In rope dyeing technique risk of paving right-left difference due to dispersion of yarns of rope form along warp width is less. In loop and slasher dyeing techniques warp yarns are in open form. In loop dyeing, yarns may need to be dipped into same bath for several times. In loop technique, yarns are dipped into impregnation bath called ‘Twin Pad’ 4 times. In warp dyeing, warp yarns are dyed continually in multiple-phase machines. Each phase comprises impregnation in leuco solution in alkali bath at low temperature. Then after squeezing, an air passing is conducted for oxidizing leucon and turning into blue and thus becoming dissoluble. System in general comprises 1 -2 wetting/washing bath, 6-8 oxidation unit dyeing bathes and 2-3 flushing baths following them. A construction appropriate for dipping and oxidation period parameters is made. The purpose of them is to provide proper impregnation of dyeing agents onto yarn and to oxidize dyeing agent before entering next bath after squeezing operation and make it usable. Indigo used in denim fabric dyeing is originally produced from leaves of indigofera tinctoria plant growing commonly in tropical subtropic (particularly India and China). Indigo warp (Slazher) system is called “Sheet” or “Slasher” dyeing method too. In the system 350-500 yarn are wrapped onto warp beams of approximately 50.000 m length and 12-16 of warp beams are placed in the front of line. Number of threads reaches 4200 - 8000 with combination of warp yarns from all beams. Then yarns at warp beams are all subjected to slasher line, continued dyeing, drying, sizing, re-drying and warp take up procedures respectively. Denim is obtained after indigo is dyed at slasher dyeing machine with full warp dyeing process, woven and then subjected to finishing and quality inspection processes. Mistakes occurring in denim fabric during acquiring, that is indigo warp dyeing process such as colour differences are noticed after having fabric form. With this process developed for this important fault aims to eliminate differentiation in colour from one side of fabric to another, right-left difference or wing difference. This case occurs due to cavity surface on squeezing rollers. The edges of the squeezing roller squeezes less because of cavity. In such case mid and side parts of fabric have more dyeing agent residuals. The cause of such non- homogenous colour distribution: because of height difference occurring in welding places having joint points (at 30 cm intervals) on squeezing roller in indigo warp dyeing machine,, it causes warp stocking in rivet (joined by welding) intervals. At the points where warp is intensive due to warp stocking dye impregnation is less and impregnation is more where warp is less. Colour (wing) differentiations occur due to difference in dye impregnation from area to area.

Today several studies have been conducted and new systems have been developed to eliminate colour difference occurring in denim fabric dyeing. One of those studies is the patent application numbered TR 2020/22850 and entitled “Double Sided, effected Denim Fabric and Production Methods”. Invention relates to a double side effected denim fabric production method comprising process steps of colouring warp yarns with indigo and/or sulphur dye agents, denim weaving of coloured warp yarns and undyed/raw weft yarns, subjecting woven denim fabric to a cationic treatment, dyeing cationic treated denim fabric by means of overdye dyeing process in order to provide colouring colourless pars of undyed inner part of warn yarns denim fabric and weft yarns added into fabric structure in uncoloured/raw fabric form and applying washing and/or mechanic grinding operations to denim fabric in order to provide appearance of warp yarns of which inner part is coloured in overdye dyeing process and weft yarns of which entire is coloured on front face of fabric and to form effect.

Another study is the invention disclosed under patent application numbered TR 2019/07259 and entitled “A method Providing Sizing Warp Yarns in homogenous manner in indigo dyeing machine". The invention relates to a method that provides homogeneous sizing of the warp yarns in the indigo dyeing machine used after dyeing of indigo warp yarns in the denim sector, and its feature and characterized by comprising process steps of the first idler roller, which ensures that the first warp coming out of the first group drying drum being directed to the sizing tub , the first immersion roller, which ensures that the first warp and the second warp being dipped, the first upper printing cylinder and the first lower printing cylinder , which leads to the second group drying battalion, the second dipping cylinder associated with the first warp, the second group drying of the second warp the second upper printing cylinder and the second lower printing cylinder and the first warp coming out of the first group drying drum, and the second warp.

Another study is the invention disclosed under patent application numbered TR 2017/12762 and entitled “Warp Dyeing Process with Rotary Rotor Spraying Machine integrated to Slasher Line”. The process, developed for dyeing warp yarns, utilized in course of weaving denims is briefly composed of 1 st application vessel, intermediate washing vessels, 2nd application vessel, rotary rotor spraying machine, aeration unit, back washing vessels, sizing vessels, drying barbans, and weaving beam wrapping mechanism, respectively, for warps taking part in the beams placed into warping creels. The patterned dyeing over preparatory plain dyeing, secondary dyeing over preparatory plain dyeing, patterned dyeing over preparatory wetting/mercerization, plain dyeing treatment over wetting/mercerization can be made through this recently developed process. The plain or effect dyeing of warp yarns is insured in this process, developed via integration of slasher and rotary rotor spraying machine, through rotary rotor spraying machine, indigo colouring agents being in the first place, following the implementation onto warp yarn of wetting, mercerization and preparatory dyeing treatments altogether or separately in the slashing machine. The dyed warps bring a natural effect to the fabric after weaving.

As a result, the need for an indigo warp dyeing machine eliminating the disadvantages available in the related art and inadequacy of existing solutions has necessitated development in the related art.

Brief Description of the Invention

Present invention relates to indigo warp dyeing machine developed for solution of issue of dyeing agent remaining in more quantity in mid and side parts of fabric defined as right-left difference or wing difference arising from cavity occurring in squeezing roller in Slasher warp dyeing machines due to failure to provide squeezing function equally as a result of less squeezing roller sides, which meets above mentioned needs, eliminates all disadvantages and brings some additional advantages.

From current case in the related art, the purpose of the invention is to eliminate colour differences (wing differences) arising out of varying dye impregnation from one area to another as a result of less dye impregnation in areas having high warps and less dye impregnation in areas having low warps because of height difference occurring in welding places having joint points (at 30 cm intervals) on squeezing roller in indigo warp dyeing machine thanks to designed new roller model.

Purpose of invention is to provide elimination of height difference causing colour difference occurring as a result of warp stocking occurring in welding parts by means of designing spiral welded system instead of flat welded system in cylinder present applications and designing rivets in a manner to be parallel.

A further purpose of the invention is to enable production in range varying from 1 cm to 100 cm between each welding by help of cylinder design.

The structural and characteristics features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations.

Brief Description of Figures n order to make the embodiment and additional members being subject of the present invention as well as the advantages clearer for better understanding, it should be assessed with reference to the fallowing described figures.

Figure 1 is schematic general view of indigo warp dyeing machine.

Figure 2 is schematic general view of rollers in indigo warp dyeing machine in the related art.

Figure 3 is schematic general view of flat welded roller in related art status.

Figure 4 is a schematic general view of spiral welded roller of invention. Figure 5 is a schematic general view of distribution of welds in roller of invention.

Figure 6 is detailed view of roller of 14 cm between welds in a preferred application of the invention.

Reference Numbers

100. Indigo warp dyeing machine

1 10. Warping creel

120. Preliminary Treatment tubs

130. Dyeing tubs

131. Roller

140. Sizing tubs

150. Accumulator

160. Beam winding

S. Roller of the related art

Detailed Description of the Invention

In this detailed description indigo warp dyeing machine (100) developed for solution of issue of dyeing agent remaining in more quantity in mid and side parts of fabric defined as right-left difference or wing difference arising from cavity occurring in squeezing roller in Slasher warp dyeing machines due to failure to provide squeezing function equally as a result of less squeezing roller sides is disclosed as an illustration solely for the purpose of better understanding of the subject and described in a manner not causing any restrictive effect.

The indigo warp dyeing machine (100) of the invention shown in figure 1 is developed for the purpose of elimination of non-homogenous colour distribution problem as a result of warp stocking in rivet (weld joined) intervals due to height difference even though less in areas in weld points of joining places (in 30 cm intervals) on rollers (S) shown in Figure 2. At the points where warp is intensive due to warp stocking dye impregnation is less and impregnation is more where warp is less. Colour (wing) differentiations occur due to difference in dye impregnation from area to area. Regarding the colour differences occurring, indigo warp dyeing machine (100) comprising spiral welded roller (131 ) shown in figure 4 and figure 5 instead of flat welded roller (S) shown in figure 3 is developed. Wing differences (left side-mid and right side) problem occurring as a result of warp stocking in former roller (S) is eliminated by help of new roller (131 ). Length of said roller (131 ) is 100-250 cm instead of the usual size of 174 cm and diameter is 20,4 cm with a maximum deviation of 3 cm.

Said indigo warp dyeing machine (100) comprises warping creel (110) where preferably 12- 16 warp beams are placed; pre-treatment tubs (120) where 12-16 beams from said creel (110) part enter in single warp direction and 3 thereof defined as pre-treatment; sizing tubs (140) where dyed warp yarns coming from dyeing tubs (130) are dipped for sizing after dried in drying tubs; accumulator (150) supplying electric energy needed for process; and beam winding (160) where warp yarns required for weaving fabric are transferred. Said indigo warp dyeing machine (100) is characterized by comprising dyeing tubs (130) also called indigo dyeing tubs coming from pre-treatment tubs (120) and where spiral welded rollers (131 ) with rivet places designed in parallel are located.

In said indigo warp dyeing machine (100) welds comprise, squeezing rollers (131 ) in a manner rivet places come under one another. There is height difference of about 0,1 mm in parts corresponding to welding places of warp yarns and not welded areas. Rollers (S) used in the related art have warp yarns stocking due to height difference of 0,1 mm and side-mid- side colour (wing) difference occur due to such stocking. Indigo warp dyeing machine (100) of the invention has welding appearance in a manner rivet places of squeezing rollers (131 ) correspond to parallel distances. In said roller (131 ) height difference in parts corresponding to welding places of warp yarns and not welded areas is distributed. Since such warp stocking does not occur in said rollers (131 ), side-mid-side colour (wing) difference problem is eliminated. In preferred application of the invention shown in Figure 6, the roller (131 ) with 14 cm distance between welds is used.