A Knit - Fabric Dyeing Machine and A Dyeing Method

The invention relates to a knit - fabric dyeing machine and a dyeing method.

The present invention is economical from the point of view that it provides lower water consumption, lower energy consumption due to lower liquid heating requirements, lower chemicals usage due to lower liquid usage, lower dyestuff consumption due to lower liquid usage, shorter dyeing process time due to lower liquid usage. For example; while existing dyeing machines make dyeing with a fabric / flotte (liquid) ratio ranging from 1/8 to 1/10, this ratio is between 1/4 to 1/6 in this invention. Therefore, the machine is economical from the point of view that it provides lower water consumption, lower energy consumption due to lower liquid heating requirements, lower chemicals usage due to lower liquid usage, lower dyestuff consumption due to lower liquid usage, shorter dyeing process time due to lower liquid usage.

Dyeing quantities of the existing machines are limited. On comparison, while capacity range of existing dyeing machines for a 25 kg dyeing machine is between 15 to 20 kg, this range in subject machine is only between 2 to 20 kg and this ratio is 65-90 kg and

10-90 kg respectively for a 100 kg dyeing machine.

Moreover, the invented machine has the ability of both dyeing knit and woven fabric.

No change is being made as to the chemical reactions of dyeing process by virtue of this machine and it provides saving up from physical processes

For example, when a dye color and process is a matter of subject, total dye percentage for a saxe (parliament) blue is 4.3 % ( everzol blue brf 150 %- 0.3 % ; everzol blue r special 4 % ).

The invention is elucidated with the attached figures whereas; Figure 1a- shows perspective view of the machine

Figure 1b- shows inflated section of the machine for machine dyeing process

Figure 2 - is a flow diagram showing dyeing steps

The parts depicted in the above figures are itemized below:

1 ) Driving Rollers / Free Rollers

2) Inlet Rollers / Injection/Spraying Rollers

3) Direction Roller / Expression/Squeeze Rollers 3a) First Expression/Squeeze Roller 3b) Second Expression/Squeeze Roller

4) Spraying Channels / Injection Rods

5) Pressurized Air Channel

6) Reducer 7) Decatizing Apparatus

8) Decatizing Gear

9) Resistance / Steam Exchanger

10) Transport Rollers

11) Filters 12) Flotte Pump

13) Transport Roller

14) Tank Upper Covers/Flexes

15) Raw Material Inlet

16) Main Body 17) Chassis

18) Raw Material and Water Inlet

19) Discharge Outlet

20) Decatizing Reducer

21) Inflated Section

Drive rollers (1) provide the transport of fabric and squeeze out the surplus liquid from fabric; inlet rollers (2) squeeze the liquid in the fabric and expand the fabric by stretching it; direction roller (3) provide the centering of fabric and prevent it to slump down to one side; injection / spraying channels (4) inject liquid to rollers from many points in both direction at inlet and outlet; pressurized air channel (5) is used to inflate tube fabric; reducer (6) turns driving rollers and decatizing gear; decatizing apparatus (7) places the fabric under the boiler by folding it; decatizing gear (8) performs the shaper function; resistance (9) is used to heat the Liquid inside the boiler, or if steam mechanism is available steam exchanger is engaged instead of resistance (9); transport rollers (10) provide the easy slippage of the fabric inside the liquid; filter (11) strains the fabric particles inside the liquid; flotte pump (12) pumps the liquid into the injection / spraying channels (4); transport roller (13) provide orientation; tank upper cover (14) is a transparent cover and can be visible from outside; raw material inlet (15) is place for entry of water, chemicals and dyeing material to tank. The main body (16) of the subject machine is made of stainless steel sheet and chassis (17) includes a chassis in order to carry out the machine. Furthermore, the machine includes raw material and water inlet (18) and discharge outlet as well as decatizing reducer (20).

The machine includes 2 driving rollers (1), 2 inlet rollers (2), a direction roller (3), 4 injection / spraying channels (4), a pressurized air channel (5), a reducer (6), a decatizing apparatus (7), a decatizing gear (8), a resistance / steam exchanger (9), 7 transport rollers (10), a filter (11), a flotte pump (12), a transport roller (13), 2 tank upper covers /flexes (14). One end of the fabric to be dyed is passed through injection rods (4) and inlet rollers (2) first and is hung down by passed over direction roller (3) and two rollers (1) and other injection rollers. The fabrics are run by means of start / forward button of the machine and the fabrics are conveyed into the machine. The machine is stopped after 5-6 meters fabrics are wrapped. The first end of the fabric is pulled using with a stick and hung out of the machine. The first and last ends of the fabrics are sewed either by hand (with needle and yarn) or by means of a overlock machine. The fabric is made as a whole fabric. The machine is re-run by means of forward button. It is continued to take the fabrics inside the machine. The widths of the fabrics are sewed either by hand or by means of a overlock machine in the type of pipe sew. The fabric is inflated in the shape of pipe using pressurized air channel (5) and the fabrics are completely taken inside the machine in order to start to process. The water as enough to the quantity of the fabric to be dyed is taken inside the machine and water is heated up to the desired temperature by means of resistance system (9) available in the machine. Heating system shall be gradual. Chemicals are also added into the machine gradually according to the quantity of the fabric to be dyed while heating process is lasting. Heated water together with chemicals are circulated by means of flotte pump (12). Heated water and chemicals are sprayed onto the surface of the fabrics over the injection channels (4) from four points. The machine is run by pressing start button. With the turning of driving (1) and inlet rollers (2), turning and circulating of the fabric between the rollers is provided. During this process, pre-treatment is made by wetting the fabric using both spraying and dipping method. After pre-treatment, the fabric is prepared for washing off / rinsing by discharging the water with chemicals presents in the tank of the machine by means of flotte pump (12). Cold and hot rinsing is being made using city water depending on condition of the fabric. After washing off / rinsing, the fabric is prepared for dyeing by re- discharging the water with flotte pump (12).

The water as needed for dyeing process is taken again and the machine is started. Chemicals and dyeing materials are added while heating process is done. Heated water and chemicals provide the dye be adapted to the revolving surface of the fabric by means of revolving rollers and injection system. At the same time, it helps the fabric be dyed by means of dipping method by immersing the fabric into the heated water which includes chemicals and color agents inside the tank of the machine and so dyeing process is finished. The water remained after dyeing is drained and rinsing cycle takes place again. Different chemicals are administered according to the desired properties of the fabric, and silicon enzyme glossing slickness providing chemicals are re-added according to glossiness, opacity, softness, hardness and surface smoothness of the fabric.

After dyeing process, the fabric stretched in rollers and cylinders are cut from the jointed seam. The fabric is taken out to the tank present in outside by running the machine reverse and expression / squeeze process is applied for approximately five minutes in fabric squeeze machine. After squeezing process, the fabric freed from water is dried in drying machine. After drying process, it is folded, rolled and serviced.

In existing dye houses, the fabrics are dyed with rope dyeing system. Rope dyeing means; the fabrics are creased just as same as seen in a rope and meshed with each other. There are no homogeneity and the distribution of the dye to everywhere of the fabric evenly is very difficult. The fabrics should be rotated very fast because of barre dyeing is the matter of subject. For example, they are rotated with a speed of 200 meters / minute and barre dyeing of the fabrics are tried to be prevented. Moreover, one revolution of the fabric is tried to be completed in 2 minutes and they are rotated more faster to manage this.

However, there is no need to this in subject homogeneous dyeing machine. The fabrics are dyed by inflating them in the shape of a tube. The fabric do not become ropes by the virtue of inflation and do not adhere to each other and do not crease. The fabrics do not have to be rotated fast since they are to be dyed by inflating and squeezing. The fabrics are inflated by means of the air in the compressor between the free roller and first expression roller (3a). Before coming to first expression roller (3a), all the dye flotte is sprayed everywhere of the fabric evenly by injecting the dye flotte inside the machine. The fabrics are squeezed between the first expression roller (3a) and second expression roller (3b). The reason of this is that the fabrics give off the dye water (flotte) to out which are absorbed by them since the mixed and creased fabrics inside the dye flotte are squeezed at the bottom. They need adsorption, shrinkage and impregnation. Thus, a smooth dyeing is obtained since colorant material quantity which should be absorbed by the fabrics in each injection is taken evenly. So, it provides that each point of the fabric which is in the shape of tube gets all material in the dye process evenly. Thus, uniform dyeing (without barre) is provided.

The water enough as to the quantity of the fabric to be dyed is loaded. Then, it is heated up to the desired temperature by means of resistance system (9) available in the machine. Heating system is gradual and chemicals are added into the machine gradually according to the quantity of the fabric to be dyed while heating process is lasting. Heated water together with chemicals are circulated. The fabric is circulated with the help of the reducer (6) while it is in a stretched state in the rollers of the machine. During this process, pre-treatment is made by wetting the fabric. The water is discharged by means of the water pump (19) present in the machine and then fabric is rinsed. The water is discharged by means of pump (19) after washing off / rinsing. The machine again takes water as needed. Chemicals and colorant materials are added after re-heating process. Heated water and chemicals provide the dye be adapted to the revolving surface of the fabric by means of revolving rollers and injection system. At the same time, it helps the fabric be dyed by means of dipping method by immersing the fabric into the heated water which includes chemicals and color agents inside the tank of the machine and so dyeing process is finished. The water and chemicals in the machine is discharged again. Required amount of cold water for washing off / rinsing is taken to the machine. If required, fastness value of the fabric is increased with the chemicals like fixers and softeners and is subjected to rinsing process again. Dyeing process is finished. After dyeing process, the fabric stretched in rollers and cylinders are cut from the jointed seam and the fabric is taken out to the tank present in outside by running the machine reverse. After that expression / squeeze process is applied for approximately 5 minutes in fabric squeeze machine. After squeezing process, the fabric freed from water is taken into tanks. The tanks are taken to drying machine and drying process is applied according to the approximate weight of fabric, subjected to the drying process for an interval of 30 to 60 minutes. After drying process, the fabric is taken into the tanks again and folding (decatizing) is made based on the weight of the fabric or it is rolled. Different chemicals are administered according to the desired properties of the fabric, and silicon enzyme glossing slickness providing chemicals are re-added according to glossiness, opacity, softness, hardness and surface smoothness of the fabric.

Working Principle of the Invention

The first end of the fabric to be dyed is passed through injection rods (4) and inlet rollers

(2) first and is hung down by passed over direction roller (3) and two rollers (1) and other injection rollers. The fabrics are run by means of start / forward button of the machine and the fabrics are conveyed into the machine. The machine is stopped after 5-6 meters fabrics are wrapped. The first end of the fabric is pulled using with a stick and hung out of the machine. The first end of the fabrics will be sewed with the last end later. The machine is re-run by pressing forward button after the first end of the fabric is hung out of the machine which will be sewed later. It is continued to take the fabrics inside the machine. The machine is stopped again when the last end of the fabric is arrived. The first and last ends of the fabrics are sewed either by hand (with needle and yarn) or by means of a overlock machine in the type of pipe sew. The fabrics are now completely taken inside the machine in order to start to process.

Process flow may be summarized in four main title as follows:

1-Pre- bleaching ; 2- Dyeing; 3- Rinsing ; 4- Finishing (fixer and softener)

In present case, the fabrics are dyed with rope dyeing system in dyeing houses. Rope dyeing means; the fabrics are creased just as same as seen in a rope and meshed with each other. There are no homogeneity and the distribution of the dye to everywhere of the fabric evenly is very difficult. The fabrics should be rotated very fast because of barre dyeing is the matter of subject. For example, they are rotated with a speed of 200 meters / minute and barre dyeing of the fabrics are tried to be prevented. Moreover, one revolution of the fabric is tried to be completed in 2 minutes and they are rotated more fast to manage this. There is no need to this in subject homogeneous dyeing machine.

The fabrics are dyed by inflating them in the shape of a tube through the section as shown in Figure 1 b. The fabrics do not become ropes by virtue of inflation and do not adhere to each other and do not crease. The fabrics do not have to be rotated fast since they are to be dyed by inflating and squeezing. The fabrics are inflated by means of the air in the compressor between the free roller and first expression roller (3a). Before coming to first expression roller (3a), all the dye flotte is sprayed everywhere of the fabric evenly by injecting the dye flotte inside the machine.

The fabrics are squeezed between the first expression roller (3a) and second expression roller (3b). The reason of this is that the fabrics give off the dye water (flotte) to out which are absorbed by them since the mixed and creased fabrics inside the dye flotte are squeezed at the bottom. They need adsorption, shrinkage and impregnation. Thus, a smooth dyeing is obtained since colorant material quantity which should be absorbed by the fabrics in each injection is taken evenly. So, it provides that each point of the fabric which is in the shape of tube gets all material in the dye process evenly. Thus, uniform dyeing (without barre) is achieved.

Different from other existing machines, any kind of fabrics is required to become tube fabrics, for example a cotton fabric should become a tube fabric by sewing its sides even if it has open width. Open width means to provide even distribution of the dye to each pore of the fabric by eliminating the unwanted cases such as creasing and piling of the fabric during dyeing process by means of feeding the fabric to the rollers (1 ,2,3) by folding it in two via its width. If it is not applicable and if the fabric is fed into the dyeing process in a way it is piled or creased, it would not be possible to distribute the dye evenly to the each pore of the fabric.

Process time of a total 12 hours is reduced to 6 hours in a manner that the present invention system requires 1.5 hours instead of 2.5 hours for pre-bleaching process in rope dyeing system; 2 hours instead of 4 hours for dyeing process; 1.5 hours instead of 4 hours for rinsing process, one hour instead of 2 hours for finishing (fixing and softening) process.

Dyeing of the fabric is finished and dyed fabric is taken to design cycle. After this step, the fabrics are packed and shipped following squeezing, drying and sanforing processes were carried out.

The sample and colors of the fabric to be dyed arrive at the dyeing house. A laboratory study is carried out for the sample fabrics sent for coloring. After laboratory study, it is sent to the customer for approval of the color. Received fabrics are weighed by raw depot, its weights (kg) and total quantity are compared with the ones written in the delivery note and are given to planning department of the dyeing house. Planning department makes a dyeing program by making a dyeing schedule including such details as in which machine in the dyeing house it will be carried out and how many kilos of dye will be used. The fabrics and colors are dyed under this program.

For example, if we assume that weight of one of the fabrics which is planned to be dyed by the planning department is 100 kg and to be dyed to green; raw depot first weighs the fabrics to be dyed to green color, opens the raw and uniform roll fabrics by passing them through roll opener machine so that they will be decatized, controls and checks the fabrics and sews each end of rolls with each other and opens them to cars in such a manner that last ends of them will be exposed. Raw fabrics opened to cars for transportation are sent to the dyeing house for dyeing. They are brought in front of dyeing machine. The fabrics are subject to two steps at the dyeing house:

A- Stage of Wet Section

B- Stage of Dry Section

A - Wet Section : The fabrics taken to dyeing machine are subject to the following steps when they are dyed. While wet processes are dyed with a flotte ratio = 1/8 to 1/10 in the dyeing houses, they are dyed with a flotte ratio = 1/4 to 1/5 in subject machine.

A.1 ) Bleaching Process : Flotte ratio is water quantity to be consumed for 1 kg fabric. For example, water consumption of subject machine is 500 liters for 100 kg fabrics while other dyeing houses use 1000 liters water for 100 kg fabrics.

Table 1 - Comparison of Chemical Material and Water Distribution

As it can be seen in the bleaching process which is the first process of dyeing, chemical material consumption decreases half in addition to 50 % water saving. Such saving is not limited with this but also includes time saving with respect to filling and discharging

1000 liters water when compared to 500 liters water.

Bleaching processes are made at 95°C. There is also a fuel saving in addition to the above saving because the steam consumed for heating 1000 liters water is twice of the steam used for heating 500 liters water.

Therefore, the savings provided with the present invention are:

1- Water amount

2- Time saving

3- Chemical material

4- Steam consumption 5- Dyestuff : It is the most important saving. At lower flotte, the colors appear minimum 20 % and maximum 35 % more dark and deep and this returns as dye saving.

Table 2 - Machine Loading Capacity According to Fabric Type

As specified below, the processes comprise a total of 14 steps namely, 4 steps for bleaching, one step for dyeing, 6 steps for rinsing, 3 steps for finishing which means water is loaded and unloaded 14 times.

A- BLEACHING

A-1 : Bleaching pre-treatment : Fabric control is done

A-2 : Rinsing : It runs only with water at 80 ⁰ C for 10 minutes.

A-3 : Anti-peroxide enzyme process : pH is adjusted between 5 - 5.5 with (1gr/lt) acetic acid. Anti-peroxide enzyme(0.8-1gr/lt) at 55°C is used. Duration is 15 minutes.

A-4 : Anti-pilling enzyme process : pH is adjusted between 5 - 5.5 with (0.5-0.8 gr/lt) acetic acid. Anti-pilling enzyme (1% - 1.5%) at 55°C is used. Duration is 20 minutes.

B - DYEING : Depending on the colorant material group used, dyeing is made either with 80 ⁰ C hot colorant material or with 6O ⁰ C cold colorant material. Generally cold (60 ⁰ C) dyes are preferred since they are much more economical.

C- RINSING

C- 1 Cold rinsing : Cold rinse overflow is made at 30 ⁰ C. Duration is 10 minutes.

Cold rinse overflow : Discharge valve is open, water filling valve is open; it loads and unloads water at the same time in order to prevent sudden decrease of the temperature and shocking (quick freezing). C-2 Acidification : It is made with (1 gr/lt) acetic acid at 50° C. Duration is 10 minutes.

C-3 Cold rinsing : It is rinsed at 80 ⁰ C . Duration is 10 minutes. C-4 Soaping : It is made with (0.5-1 gr/lt) soap at 95°C . Duration is 10 minutes. C-5 Hot rinsing : It is rinsed at 80 ⁰ C . Duration is 10 minutes. C-6 Lukewarm rinsing : It is rinsed at 50 ⁰ C . Duration is 10 minutes.

After dark and very dark colored dyeing, soaping process can be made two times that is, one more soaping process may be inserted .

D-FINISHING PROCESSES

D- 1 Anti-pilling : pH is adjusted between 5 - 5.5 with (1gr/lt) acetic acid). Anti - pilling enzyme.(0.5% - 0.8%) at 55°C is used. Duration is 15 minutes.

D-2 Fixing : pH is adjusted between 5 - 5.5 with (0,5 gr/lt) acetic acid. Fixator (1-2%) is used at 40 -50 ⁰ C. Duration is 20 minutes.

D-3 Softening : pH is adjusted as 5.5 with (0.5-0.8gr/lt) neutral acid. Cationic softener (1-3%) at 4O ⁰ C is used. Duration is 20 minutes.

Neutral acid is used in final softening water. Acetic acid is volatile and therefore is not used. In the later processes, it can evaporate due to heat for example in the dry processes like drying. However, neutral acid cannot easily evaporate and remain on the fabric at least 20 3- 30 days. The pH value desired in the fabric is latest 7,5, that means it should be neutral. A pH value ranging between 5.5 to 7.5 do not harm skin of a human body.

B - Dry Section

2.1 - Balloon Squeezing : Water of the fabrics come from dyeing is squeezed out.

2.2 - Drying or Stenter : Tube fabrics are dried by passed through drying machine and open width fabrics are dried by passed through stenter. 2.3 - Sanforing : After the fabrics finally dried, they are sanfored for ironing at a desired width and weight.

3 - PRODUCTION DEPOT

Each roll of sanfored fabric is packed with nylon one by one and weighed in depot. Each roll is labeled by indicating the customer name, fabric name, color and kilogram.

4 - SHIPPING

The fabrics for which delivery notes issued are ready for shipment.