Description

POLISHING MACHINE FOR PROCESSING PILE

Technical Field

[1] The present invention relates to a polishing machine capable of imparting excellent properties, such as gloss and volume, to pile (hair) of a woven fabric web, in which "90 degree counterclockwise-rotated sigma (L)" (i.e., "

") shaped oblique grooves or "L" (i.e., "

") shaped oblique grooves are formed in the outer periphery of a pair of heating cylinders, which are arranged in a line, and the oblique grooves include three clockwise oblique grooves and three counterclockwise oblique grooves, which are equally and symmetrically arranged with respect to each other. Background Art [2] The present invention also relates to a heating cylinder unit of the polishing machine for processing a fabric web having piles in order to make the fabric web glossy and voluminous. When the fabric web is carried by the tension of a driving roller and is spread on a rotating rubber conveyor belt, which is in elastic contact with first and second rotating heating cylinders, the pile on the surface of the fabric web is drawn into the "90 degree counterclockwise-rotated sigma(L)" (i.e., "

") shaped oblique grooves or the "L" (i.e., "

") shaped oblique grooves in the outer periphery of the heating cylinders. At the moment that a corresponding portion of the fabric web escapes from the leading edge 4-13 of the grooves, bursting and beating effects take place to provide a gloss to the deepest portions of the pile of the fabric web and erect the deepest portions of the pile of the fabric web (i.e., erect the pile along the entire length of the pile), so that the pile is smoothly set and becomes voluminous. The fabric web is rubbed against the outer periphery of the heating cylinders of the polishing machine when it is being conveyed along the latter, so that the pile becomes glossy, like mink hair. Disclosure of Invention

Technical Problem

[3] According to Korean Patent No. 417499 (heating cylinders having a diameter of

320mm), granted to the applicant, heating cylinders having a diameter of 320mm, manufactured in Japan, and heating cylinders having a diameter of 260mm, man-

ufactured in Europe and/or China, four (4) oblique grooves are formed in the outer periphery of the heating cylinders. In this case, electric heater rods are disposed in the space inside the heating cylinders, in detail, are inserted into heater rod insertion flange holes to directly heat the heating cylinders without the use of a radiant heat transferring pipe, which is made of a rolled plate. This type of heating cylinder is useful for a small volume. However, the size of the inner space is increased in accordance with an increase in the size of the heating cylinders. Hence, when the heating cylinders are heated, the heater insertion flanges block convection in the heating cylinders, so that the flow of heat is not uniform, and heat distribution in the outer periphery of the heating cylinders exhibits great temperature differences in left, middle and right points. Accordingly, it becomes difficult to form a normal fabric web having pile. [4] In addition, in the case where the diameter of the heating cylinders is increased, the

"90 degree counterclockwise-rotated sigma(L)" (i.e., "

") shaped oblique grooves or "L" (i.e., "

") shaped oblique grooves may be formed with different numbers of clockwise and counterclockwise grooves, such as five (5) grooves (2 grooves, 3 grooves) or seven grooves (3 grooves, 4 grooves), that is, with odd number of grooves. Then, left and right ironing areas are not symmetric or balanced, so that a polishing effect or function is not enabled. In the case where the "

" shaped oblique grooves or "

" shaped oblique grooves are formed, with an even number of 8 or more, on the outer periphery of the heating cylinders, it is inefficient to manufacture the machine or process the fabric web, and economic competitiveness is poor. Technical Solution

[5] The present invention has been made to solve the foregoing problems with the prior art, and therefore an aspect of the present invention provides a polishing machine for processing a fabric web having pile, comprising first and second heating cylinders, each of which has a diameter of 380 to 480mm, wherein each of the heating cylinders has three clockwise oblique grooves and three counterclockwise oblique grooves formed in the outer periphery thereof, wherein each of the oblique grooves has a "90 degree counterclockwise-rotated sigma(L)" (i.e., "

") shaped cross section, which is used for both forward and backward rotation to

impart orientation to the pile, or an "L" (i.e., "

") shaped cross section, which is used only for forward rotation, and wherein the clockwise oblique grooves alternate with the counterclockwise oblique grooves in an equal and symmetric configuration.

[6] According to an embodiment of the polishing machine, a plurality of flanges may be spaced apart from each other at a predetermined interval, and be fixed to an outer periphery of an inner pipe 4-2, which is disposed in a space inside the heating cylinder 4 or 4a, each of the flanges having a plurality of guide holes, into each of which an electric heater rod 4-5 is inserted and assembled therewith, a heat blocking pipe 4-4 made of a rolled plate may be assembled and attached to an outer periphery of the flanges, so that the heat blocking pipe 4-4 blocks the heat of the heater rods and transfers radiant heat, thereby heating the heating cylinder, and a compartment 4- Ia may be formed by assembling a heating cylinder pipe 4-1 outside the heat blocking pipe 4-4 to maintain a uniform temperature variation of +2.5 ⁰ C using radiant heat.

Advantageous Effects

[7] According to the present invention as set forth above, the diameter of the heating cylinders of the polishing machine is enlarged up to a size of 380 to 480mm from a conventional size of 260 to 320mm, and three (3) clockwise oblique grooves and three (3) counterclockwise oblique grooves are equally and symmetrically formed in the surface of the heating cylinders, so that the clockwise oblique grooves alternate with the counterclockwise oblique grooves. Then, various fabric webs having pile can be imparted with high quality by rotating the heating cylinders of the polishing machine of the present invention at the same rate as the conventional heating cylinders.

[8] Furthermore, since the inner pipe and the heat blocking pipe 4-4, which is made of a rolled plate to transfer radiant heat, are disposed in the space inside the heating cylinders, the diameter of the heating cylinders can be increased to a range from 380 to 480mm, and the temperature variation on the outer periphery of the heating cylinders is minimized (±2~3°C). Accordingly, it is possible to produce fabric webs having excellent properties, such as gloss and volume to process fabric webs having high quality, and to realize high productivity.

Brief Description of the Drawings

[9] FIG. 1 is a configuration view illustrating an apparatus of the present invention;

[10] FIG. 2 is enlarged views of the part "A" shown in FIG. 1;

[11] FIG. 3 is enlarged views of the part "B" shown in FIG. 2;

[12] FIG. 4 is an assembly view illustrating a process of manufacturing the heating cylinder of the present invention;

[13] FIG. 5 is a perspective view illustrating the heating cylinder of the present invention;

[14] FIG. 6 is a cross sectional view of FIG. 5;

[15] FIGS. 7 and 8 are cross-sectional views illustrating oblique grooves;

[16] FIG. 9 is a cross sectional view taken along the line C-C of FIG. 5;

[17] FIG. 10 is a perspective view illustrating a conventional heating cylinder;

[18] FIG. 11 is a cross sectional view of FIG. 10;

[19] FIGS. 12 and 13 are cross sectional view illustrating oblique grooves of a conventional heating cylinder;

[20] FIG. 14 is a cross sectional view taken along the line C-C of FIG. 10;

[21] FIGS. 15 and 16 are configuration views illustrating oblique grooves of the present invention;

[22] FIGS. 17 and 18 are configuration views illustrating conventional oblique grooves; and

[23] FIGS. 19 and 20 are configuration views illustrating temperature check points of the heating cylinder.

[24] <Major Reference Numerals of Drawings>

[25] 1-1: fabric web to be processed 1-2: processed fabric web

[26] 2-1, 2-2: adjustment guide roller 2a- 1, 2a-2: conveyor belt

[27] 3, 3a: conventional first and second heating cylinder

[28] 3b- 1: "

" shaped oblique groove [29] 3b-2: "

" shaped oblique groove

[30] 3- 1 : heating cylinder pipe 3-3: heater insertion guide flange

[31] 3-3a: electric heater insert hole

[32] 3-5: electric heater 3-6: slip ring

[33] 3-7: carbon brush 3-8: bearing case

[34] 3-9: slip shaft 3-10: driving pulley shaft

[35] 3-11: driving pulley 3-12: electric heater cover

[36] 4, 4a: heating cylinder

[37] 4b- 1: "

" shaped oblique groove [38] 4b-2: "

" shaped oblique groove

[39] 4- 1 : heating cylinder pipe 4- 1 a: compartment

[40] 4-2: inner pipe 4-3: flange

[41] 4-3a: heater rod insertion guide hole

[42] 4-4: heat blocking pipe 4-5: electric heater rod

[43] 4-6: slip ring 4-7: carbon brush

[44] 4-8: bearing case 4-9: slip shaft

[45] 4-10: driving pulley shaft 4-11: driving pulley

[46] 4-12: electric heater cover 4-13: leading edge of groove

[47] 5- Ia, 5-2a: adjustment screw bolt handle

[48] 5-1, 5-2: air cylinder 6-1, 6-2: guide roller

[49] 7: moisture supply 8-1, 8-2: dust inlet

[50] 9: guide roller 9- 1 : brake roller

[51] 9-2: driving roller 9-3: carrying driving roller

[52] 10: tension bar 11 : cam for enabling vibrating drop

Best Mode for Carrying Out the Invention

[53] Hereinafter the present invention will be described more fully in conjunction with the accompanying drawings, in which exemplary embodiments thereof are shown. While the present invention will be described in connection with the accompanying drawings, it is to be understood that the drawings only illustrate examples of the idea of the present invention, and that the present invention is not limited to the drawings.

[54] In the detailed description of the present invention, well-known functions or constructions will not be described in detail, since they would unnecessarily obscure the understanding of the present invention.

[55] Hereinafter the present invention will be described in detail according to a polishing process, which is conducted using the polishing machine of the present invention.

[56] As shown in FIGS. 1 and 2, a fabric web 1-1 to be processed is carried to a first conveyor belt 2a- 1 through a guide roller 9, a tension bar 10, a brake roller 9-1, a driving roller 9-2 and a guide roller 6-1.

[57] The web 1-1 carried to the first conveyor belt 2a- 1 is in elastic contact with the first heating cylinder 4, which is positioned adjacent to the first conveyor belt 2a- 1, when it passes through the first conveyor belt 2a- 1 and a first heating cylinder 4.

[58] An adjustment guide roller 2- 1 is provided in the rear of the first heating cylinder 4.

The adjustment guide roller 2- 1 is movable upward behind the first heating cylinder 4, so that the length of the contact area between the web 1-1 and the first heating cylinder 4 can be adjusted. That is, when a switch of a control panel (not shown) is manipulated, an air cylinder 5-1 is actuated to move the adjustment guide roller 2-1

upward behind the first heating cylinder 4, and a first adjustment screw bolt handle 5- Ia drives the adjustment guide roller 2-1 forward or rearward. Accordingly, the position of the air cylinder 5-1 can be freely adjusted, so that the length of the contact area of the web 1-1 can be adjusted as desired.

[59] The diameter of the first heating cylinder 4 ranges from 380 to 480mm, and oblique grooves 4b- 1 are formed in the outer circumference of the first heating cylinder 4. As shown in FIGS. 5, 15 and 16, there is a total of six (6) oblique grooves, including three (3) clockwise grooves and three (3) counterclockwise grooves, in which the clockwise grooves alternate with the counterclockwise grooves. Provided the axis of the first heating cylinder 4 is horizontal, those that are inclined from the left to the upper right of the cylinder are called "clockwise oblique groove" and those that are inclined from the right to the upper left of the cylinder are called "counterclockwise oblique groove."

[60] Each of the oblique grooves 4b- 1 may have a cross section in the shape of a "

" or a "90 degree counterclockwise-rotated sigma (L)," as shown in FIGS. 7 and 15.

When the cross section of the oblique grooves 4b- 1 has this shape, a polishing process can be performed not only in the case where the heating cylinder rotates forwards, but also in the case where the heating cylinder rotates backwards. [61] Accordingly, the rotating direction of the first heating cylinder 4 and the elastic contact area in the polishing process can be properly adjusted, so that the polishing can be optimally performed according to the type of web. [62] Of course, the oblique grooves 4b- 1 of the first heating cylinder 4 can have a cross section in the shape of an "

", as shown in FIGS. 8 and 16. In this case, the polishing can be performed by rotation in one direction.

[63] After the web is first polished through the first heating cylinder 4, the first conveyor belt 2a- 1 and the adjustment guide roller 2-1, it is carried to a second conveyor belt 2a-2 and a second heating cylinder 4a through the first driving roller 9-2 and the guide roller 6-2.

[64] As shown in FIGS. 1 and 3, the first-polished web is second polished when it passes through the second conveyor belt 2a-2 and the second heating cylinder 4a. During the second polishing, the web maintains elastic contact with the second conveyor belt 2a-2 and the second heating cylinder 4a. An adjustment guide roller 2-2 for the elastic contact area is provided in the rear of the second heating cylinder 4a. When a switch of a control panel (not shown) is operated, an air cylinder 5-2 regulates the adjustment guide roller 2-2, and thus it moves up and down, and a second adjustment screw bolt handle 5-2a regulates the second adjustment guide roller 2-2 in forward and backward

directions, so that the length of the contact area of the web can be freely adjusted. These features are the same as in the case of the adjustment roller 2-1.

[65] As in the case of the first heating cylinder 4, the diameter (φ) of the second heating cylinder 4a ranges from 380 to 480mm, and oblique grooves are formed in the outer circumference of the second heating cylinder 4a. Each of the oblique grooves has a cross section in the shape of a "90 degree counterclockwise-rotated sigma (L)" (i.e., "

") or an "L" (i.e., "

"). In addition, as shown in FIGS. 5, 15 and 16, a total of six (6) oblique grooves includes three clockwise oblique grooves and three counterclockwise oblique grooves, in which the clockwise oblique grooves alternate with the counterclockwise oblique grooves. This configuration is the same as that of the first heating cylinder 4. [66] In the second heat cylinder 4a, it is more preferable that the oblique grooves 4b-2 have an "

" shaped cross section.

[67] After being second polished by the second conveyor belt 2a-2, the second heating cylinder 4a and the adjustment guide roller 2-2, the web is drawn out through the driving roller 9-2, a guide roller 9, a cam 11, which provides oscillating drop to the fabric web, and a web conveyance driving roller 9-3.

[68] Between the first driving roller 9-2 and the first conveyor belt 2a- 1, there is provided a moisture supply 7, which sprays steam to the web 1-1.

[69] While conventional heating cylinders 3 and 3a have four oblique grooves 3b- 1 and

3b-2, the present invention provides a total of six oblique grooves 4b- 1 and 4b-2, consisting of three clockwise grooves and three counterclockwise grooves. That is, the number of oblique grooves of the present invention is increased from that of the conventional art. In the case of polishing, the heating cylinders of the present invention can be rapidly rotated at a rotation speed of 850 RPM, which is the same as that of the conventional heating cylinders 3 and 3a, having a diameter of 260 to 320mm. Accordingly, the elastic repulsive force that is applied to the web when it is passed through the heating cylinders 4 and 4a is also increased by about 1/3, so that various types of fabric webs having pile can be polished with a high quality and an improved productivity.

[70] While the present invention has been described with reference to a double polishing machine in which the first heating cylinder 4 is vertically separated at a certain angle from the second heating cylinder 4a in one frame, this is not intended to limit the present invention. The present invention is also applicable to a single polishing

machine having only one heating cylinder.

[71] In addition, for the purpose of the orientation of the fabric pile, the first and second heating cylinders can be provided with the "

" shaped oblique grooves 4b- 1, which can be used both in forward and backward directions. Alternatively, both the first and second heating cylinders can be provided with the "

" shaped oblique grooves 4b-2 in the case where the cylinders are used only in a forward direction.

[72] The heating cylinders of the present invention are devised with a diameter increased up to 380 to 480mm and with the capability of generating internal radiation heat. A heat cylinder pipe 4-1 is bored in the inner periphery thereof, and an inner pipe 4-2 having a diameter of 216mm is inserted into the center of the bored heat cylinder pipe 4-1. A plurality of heater insertion guide flanges 4-3, spaced apart from each other by a predetermined interval, is arranged on and fixed to the outer periphery of the inner pipe 4-2. Here, a plurality of electric heater rod insertion guide holes 4-3a, into each of which an electric heater rod will be inserted, is formed in the flanges by drilling. A heat blocking pipe 4-4, fitted around the flanges 4-3, is made of a rolled plate to shield or disperse direct heat from the heater rods, thereby uniformly applying radiation heat. In this fashion, the entirety of the inner pipes is manufactured so as to provide a seal. The heat blocking pipe 4-4 is heated to radiate the heat of the electric heater rods 4-5, so that the outside heating cylinder pipe 4-1 is not directly heated. A slip shaft 4-9, a driving pulley shaft 4-10 and an electric heater cover 4-12 are placed on opposite ends of the heating cylinder, to which the heat blocking pipe 4-4 is assembled, thereby forming a compartment 4- Ia, which stores heat. The compartment 4- Ia is devised in order to heat the heating cylinders 4 and 4a using radiant heat, and makes it possible to remove convection-preventing elements (e.g., heater rod flanges) inside the heating cylinders 4 and 4a. By the use of the compartment 4- Ia, convection in the air is not isolated, and the heating space is minimized. Accordingly, when a plurality of the electric heater rods 4-5, which generate uniform heat, are inserted and assembled into the heating cylinders 4 and 4a and then actuated therein, it is possible to maintain the temperature difference between the left, middle and right portions of the surface of the heating cylinder 4 and 4a constant within a range of ±2~3°C. Accordingly, heating cylinders are significantly inventive over the conventional art.

[73] The present invention also provides a heating cylinder unit of the polishing machine for processing a fabric web having pile in order to make the fabric web glossy and voluminous. The diameter of the heating cylinders is 380 to 480mm. A total of six (6)

oblique grooves, which include three "90 degree counterclockwise-rotated sigma (L)" (i.e., "

") shaped oblique grooves 4b- 1 and three "L" (i.e., "

") shaped oblique grooves 4b-2, is symmetrically formed on the outer periphery of the cylinders. When the fabric web is spread and carried on a rotating rubber conveyor belt, which is in elastic contact with the rotating heating cylinders, the pile on the surface of the fabric web is drawn into the "

" shaped oblique grooves 4b- 1 and/or the "L" (i.e., "

") shaped oblique grooves 4b-2 on the outer periphery of the heating cylinders. At the moment that a corresponding portion of the fabric web escapes from the leading edge 4-13 of the grooves, a bursting and beating effects take place to thus erect the pile of the fabric web including the deepest portions thereof (i.e., erect the pile along the entire length of the pile), so that the pile becomes glossy and smoothly set, to thus be voluminous. The fabric web is rubbed against the outer periphery of the heating cylinders of the polishing machine while it is carried along the latter, so that the pile becomes glossy, like mink hair. If the diameter is not in the range from 380 to 480mm but is less than 380mm, the conventional problems with the diameter of 320mm also occur. If the outside diameter exceeds 480mm, the machine becomes too bulky, thereby making the manufacture thereof difficult, the heating cylinders cannot rotate at 850 RPM, and vibration creates various problems. Normal operation can be enabled only in a diameter range from 380 to 480mm, within which the temperature variation of the heating cylinders can be maintained uniform. The "

" shaped oblique grooves 4b- 1 and/or the "

" shaped oblique grooves 4b-2, which include a total of six (6) grooves, including three clockwise oblique grooves and three counterclockwise oblique grooves, are formed in the outer periphery of the heating cylinders. The oblique grooves are optimally arranged to be equally distributed and symmetrical in forward and backward directions. When the fabric web 1-1 passes through the moisture supply 7, which sprays steam to the fabric web, a high quality fabric web can be produced.

[74] [Experimental Example]

[75] A. Heating Cylinder Diameter: 400mm

[76] An experiment was performed on a heating cylinder having a 400mm diameter

according to the present invention. A compartment 4- Ia was provided on the outer periphery of the flanges, into which electric heaters were inserted, and a heating cylinder pipe 4-1 was provided outside of the compartment 4- Ia. Since the variation in heat that is applied by radiant heat to the entire outer periphery of the heating cylinder pipe 4-1, was reduced to the range of ±2~3°C, the size of the heating cylinders 4 and 4a was able to be within the range from 380 to 480mm.

[77] When the inventor performed the experiment on the heating cylinder, surface temperature variation showed the results reported in Table 1 below and FIGS. 19 and 20.

[78] Table 1

Comparison of Surface Temperature of Heating Cylinder (Heating Temperature 15O ⁰ C, Unit: ⁰ C)

[79] In Table 1, the left part indicates the result of an inventive example, in which the diameter was 400mm and there were six oblique grooves, and the right part indicates the result of a conventional example, in which the diameter was 320mm and there were four oblique grooves.

[80] FIG. 19 indicates temperature check points on the six grooves of the inventive example having the diameter of 400mm, and FIG. 20 indicates temperature check points on the four grooves of the conventional example having the diameter of 320mm.

[81] As can be seen from the above experiment results, the surface temperature variation of the heating cylinder of the present invention was ±2.5 ⁰ C, which is significantly different from the surface temperature variation of ±5.5 ⁰ C of the conventional heating cylinder.

[82] B. Number of "

" Shaped Oblique Grooves 4b- 1 or "

" Shaped Oblique Grooves Formed in the Outer Periphery of Cylinder

[83] - Five (5) grooves: Since two clockwise grooves and three counterclockwise grooves are formed in the surface of an iron, the effect of polishing the surface of a fabric web having pile is not balanced due to the different numbers of oblique grooves beating the left and right surface portions. Accordingly, different surface conditions are obtained and grooves are not uniformly formed.

[84] - Six (6) grooves: Three clockwise oblique grooves and three counterclockwise oblique grooves are arranged on the surface of an iron, and thus the effect of processing the left and right surfaces is optimal.

[85] - Seven (7) grooves: Since three clockwise grooves and four counterclockwise grooves are formed in the surface of an iron, the effect of polishing the surface of a fabric web having pile is not balanced due to the different numbers of oblique grooves beating the left and right surface portions. Accordingly, different surface conditions are obtained and it is impossible to mechanically form uniform grooves.

[86] - Eight (8) grooves: Four clockwise oblique grooves and four counterclockwise oblique grooves are arranged in the surface of an iron, and thus the effect of processing the left and right surfaces is symmetrical. In the case of a heating cylinder having a diameter ranging from 380 to 480mm, more grooves make the polishing area smaller than the four grooves while increasing cutting loss. Furthermore, the polishing effect is rarely obtained, and the manufacture of the cylinder is difficult.

[87] When the "

" shaped oblique grooves 4b- 1 or the "

" shaped oblique grooves are formed in a number of 5, 7 or 8 on the outer periphery of the cylinder, the above-mentioned problems occur. However, the use of six oblique grooves does not create such problems, so that the fabric web having pile can be optimally processed. Accordingly, the cylinder of the present invention has six oblique grooves.