The present invention relates to finishing of fabric used in textile industry. This invention particularly relates to an improved padder with variable micro slits providing efficient finishing of fabric. More particularly this invention relates to padder which applies required amount of solution of chemicals with water to fabric.

BACKGROUND OF THE INVENTION

Textile fabric in raw form is very rough which is known as Grey cloth. This grey cloth is treated with different chemicals/water to impart smoothness and to achieve the required properties like feel, drape etc. in finished fabric. Generally, fabric is made of fibers weaved lengthwise and widthwise. To treat the fabric the treating chemicals are to be applied evenly and everywhere meaning all over the fibers. The fabric requires moisture level of around 30% by weight for even application of the chemicals.

The fabric is generally treated by dipping it into the solution of chemicals dissolved in water in required amount. The fabric absorbs the said solution. The fabric is further passed through a padder or mangle.

A padder or a mangle is a device to press the fabric between two rollers to squeeze out the water from the fabric. Two steel rollers with rubber coating over the surface are pressed against each other by pneumatic pressure being applied by pneumatic cylinders. The rollers have different hardness so that one is pressed more than the other. One roller is driven by a motor through a gear box. As soon as the other roller is pressed against this driven roller, the same starts rotating because of friction and physical contact. The fabric is passed through the mating area of these rollers known as nip in textile terminology. When the rollers are pressed against each other, the following two actions take place:

The fabric is pulled in depending on direction of rotation. It is squeezed between two rollers to expel as much water as possible. However moisture to the tune of 55 % still remains in cotton fabric. Any further pressure may damage the fabric. The remaining water is around 45% in blended fabric.

Further the fabric is passed through an oven or any other heating media where the excess water is removed in the form of vapor. The temperature also helps in settling the chemical reaction.

The known inventions in general involve excess usage of water which is to be removed at later stage by heating. This heating incurs usage of mostly thermal energy or other source of energy which in turn makes it costlier and non- environment friendly.

DISADVANTAGES OF PRIOR ART

As explained above, the known padders have many downsides;

• They involve extensive squeezing of fabric in which excessive pressure may damage the fabric.

• Many a times they do not treat the fabric evenly.

• They require very high thermal energy for drying the fabric as subsequent process.

• They are not environment friendly because of heavy water usage for treatment.

• They do not have mechanism to treat the top and bottom part of the fabric differently if required. ADVANTAGES OF THE PROPOSED INVENTION

1. As only required amount of the said solution can be applied on the cloth, subsequent drying process requires very less amount of energy. In turn the proposed invention saves around 40 % of energy used in Stenter machine for drying the fabric.

2. The proposed invention treats the fabric by applying solution of water with chemicals in exact amount thus saving water significantly. Water is natural resource which is becoming scarce and hence this advantage of saving water indirectly helps in saving environment.

3. The proposed invention treats the fabric by applying solution of water with chemicals in exact amount in turn using only required amount of chemical. Thus making it economical. Moreover, it also saves in unnecessary wastage of said chemicals and making it environment friendly.

4. The proposed invention uses the controller which controls the micro slits when the speed and/or thickness of the fabric vary.

5. This invention also allows the treatment of the said solution on top and bottom side in different proportion and it also allows to treat top and bottom with different solutions if need comes. If only one side of the fabric is to be treated it is also possible to turn off the micro slit assembly of the other side. This is not possible when the solution is applied by dipping the fabric in solution as being done in all conventional padders.

6. The proposed invention is efficient yet simple to use and maintain. The proposed invention focuses on optimum usage of water and thus greatly reducing the process of heating and making the invention significantly efficient. This invention proposes to apply the exact amount of solution i.e. chemicals dissolved in water which is controllable.

Thus in the proposed invention there is no wastage of chemical and water. Moreover both the top and bottom part of the fabric can be treated with different solutions if required. Moreover if only one side of the fabric is to be treated then the micro slit assembly of the other side can be turned off.

OBJECTS OF THE INVENTION

The main object of the invention is to apply solution of water with chemicals evenly on the fabric in required amount. Thus significant amount of solution is saved which makes the invention relatively economical and environment friendly.

Another object of the invention is to apply solution of water with chemicals in required amount. Thus significant amount of water is saved making environment friendly.

The further object of the invention is to save significant amount of energy used in textile machine for subsequent drying of fabric by minimizing the drying requirement.

The further object of the invention is to make it possible to apply the chemical/liquid on topside or bottom side or both side of the fabric as per user requirement. Even different type of solutions can be applied on top and bottom side as per user requirement. The further object of the invention is to control the micro slits when the speed and/or thickness of the fabric varies with the help of controller.

The further object of the invention is to provide microslit padder which is simple to use and require low maintenance.

SUMMARY OF THE INVENTION

Accordingly to achieve the aforesaid objects, present invention provides a variable micro slit padder to provide exact amount of solution to be applied on fabric for treatment. The said variable micro slit padder is mainly characterized by:

Plurality of micro slit assembly comprises of plurality of microslit with plurality of microslit blade and plurality of actuator motor providing either tilting movement which has plurality of wheel, plurality of wheel pinion, blade shaft and actuator motor or sliding movement which has plurality of sliding blade guide, plurality of housing, plurality of sliding bush, plurality of blade shaft and plurality of connecting piece;

Programmable Logic Controller or micro processor based controller for accurate functioning of microslits which calculates the accurate opening of microslit and sends according signal to plurality of actuator motor;

Plurality of chemical tanks for the each of the plurality of the micro slit to treat the top and bottom side of the fabric separately that maintains the level of solution with the help of plurality of control valve, plurality of level controlling sensor and plurality of pump;

Plurality of over flow tanks with respective plurality of micro slit to collect excess solution with the help of plurality of overflow sheet and to maintain the level of the solution with plurality of the sensor of the overflow level controller and plurality of guided rollers for the swift movement of the fabric.

According to an embodiment of the present invention plurality of micro slits are used to treat top and the bottom side of the fabric separately using the solution stored in plurality of chemical tanks.

According to another embodiment of the present invention Programmable Logic Controller or micro-processor based controller herein after referred to as controller is fed various parameters such as weight of fabric in GSM (grams per square meter), moisture or solution to be applied to the fabric as percentage etc. by the user and also receives continuous feedback of the fabric speed as input which helps the controller to calculate the accurate value of opening of the microslit either similar or different signal to top and bottom microslits.

According to one of the embodiments of the present invention, the excess chemical solution after the treatment is collected in the plurality of overflow tank which is further sent back to respective chemical tank.

According to another embodiment of the present invention fabric is guided over the plurality of guiding rollers, which are placed apart for the swift movement of the fabric.

BRIEF DESCRIPTION OF THE DRAWINGS:

Fig. 1 shows the block diagram of the control system in accordance with the present invention.

Fig. 2 shows the isometric view of the present invention having fabric moving on the rollers with the contact with the micro slits. Fig. 3 shows the side view of the present invention.

Figs. 4 shows the top and side view of the micro slit assembly with respective chemical tank. _r

Fig. 5 shows perspective view of Microslit assembly in accordance with the invention proposing tilting movement.

Figs. 6A and 6B show cross section view of Microslit assembly in accordance with the invention proposing tilting movement in open and closed position respectively.

Fig. 7 shows cross section and top view of Microslit assembly in accordance with the invention proposing sliding movement.

Figs. 8A and 8B show cross section view of Microslit assembly in accordance with the invention proposing sliding movement in open and closed ^r position respectively.

DETAILED DESCRIPTION OF THE INVENTION

The above, and the other objects, features & advantages of invention will become apparent from following description read in conjunction with the accompanying drawings.

It is known that grey cloth should be treated with different chemicals/ water to attain certain properties. The fabric is generally treated with the solution of chemicals dissolved in water herein after referred to as solution in required amount and later heated to remove excess water. The fabric is passed through a padder or mangle where the fabric absorbs the said solution while dipped into solution tank and the excess solution is squeezed out between two rollers of padder and then it is passed through stenter for removing the water by heating in the stenter.

Accordingly, present invention herein proposes variable micro slit padder to treat the fabric with required amount of the said solution thus making the padder efficient. Microslit is "precisely controllable opening in the form of horizontally spread slit", at the bottom of a tank.

Therefore, in accordance with the present invention, a new and improved variable microslit padder is introduced that comprises of Guiding rollers for the movement of the fabric, plurality of micro slits to treat the fabric, blade assembly of the micro-slit, plurality of chemical tanks for the micro slit to treat the top and bottom side of the fabric separately, a controller to control the opening and closing of the micro-slits, over flow tanks for the chemical containers.

The fig 1 shows the block diagram of the variable micro-slit padder control system. There is a controller (C), which controls the opening and closing of micro slit. Initially, the controller (C) is provided with inputs such as weight of fabric in GSM (grams per square meter), moisture or solution to be applied to the fabric as percentage, continuous feedback of the fabric speed and start signal from the machine. The percentage of moisture is weight of moisture in fabric per square meter to weight of one sq. meter of completely dry fabric. When the textile machine starts, an according input signal from the machine drive motor (to which the microslit padder is attached) is fed to the controller (C). The controller (C) calculates and provides either similar or different signal to top and bottom microslits depending on the inputs fed.

As shown in fig 2 of the present invention, fabric (10) is guided over the plurality of guiding rollers (9), which are placed apart for the swift movement of the fabric (10). The horizontally stretched fabric (10) is treated with the solution with the help of the plurality of microslit assembly (A) and (B) to treat on the top and on the bottom side of the fabric (10) respectively. The plurality of microslits (3) is kept throughout the width of the fabric (10) and is provided with the solution from their respective chemical tank. -

As shown in fig 3and 4 of the present invention, fabric (10) is guided over the plurality of guiding rollers (9). The plurality of microslits (3) is kept throughout the width of the fabric (10) and is provided with the solution from their respective chemical tank (1). The control valve (2) is placed in each of the chemical tank (1), which controls the level of solution in the chemical tank (1). When the plurality of microslits (3) open according to the signal from controller (C), the solution flows through the controlled opening throughout the width of the plurality of micro slit (3). The fabric (10) passes over or runs over the tip of the said plurality of microslits (3) and comes into the physical contact of the solution flowing. The fabric (10) absorbs the solution and gets moist. In case when the width of the fabric (10) is less than the width of the plurality of microslit (3), the excess solution drains or spills over the plurality of overflow sheet (4) and is collected into plurality of overflow tank (5). When the level in the plurality of over flow tank (5) touches the respective plurality of sensor of overflow level controller (6), the pump (7) starts and pushes the solution to the storage tank (not shown in the figure). While the fabric (10) is running over the guiding rollers (9) and the solution flows through the said plurality of microslits (3), the level in the chemical tank (1) gradually decreases. The plurality of level controlling sensor (8) senses the level and controls the level of the solution in the plurality of chemical tank (1) through level controller (not shown in fig.). The plurality of level controlling sensor (8) helps the plurality of chemical tank (1) to maintain required level of the solution through the plurality of control valve (2) receiving the solution from the storage tank (not shown in fig.) The plurality of level controlling sensor (8) can be of on/off type or PID type preferably of PID type level controlling sensor that provides precise results. The actuator of microslit blade assembly can be operated mainly in two ways:

Tilting movement Sliding movement

As shown in fig. 5, microslit blade assembly for tilting movement comprises of microslit blade (3.1), plurality of wheel (3.2), plurality of wheel pinion (3.3), blade shaft (3.4) and actuator motor (3.5). The microslit blade (3.1) is horizontally placed over the chemical tank (1) in such a way that it either opens or closes the bottom of the plurality of chemical tank (1) as per the signal from the controller (C) and accordingly allow the solution to flow out of the plurality of chemical tank (1). The plurality of wheel (3.2) is connected to the plurality of microslit blade (3.1) at both the ends. The plurality of shaft (3.4) passes through the plurality of wheel (3.2) longitudinally. The plurality of wheel (3.2) has plurality of pinion (3.3) where the wheel - pinion arrangement works as gear mechanism. The actuator motor (3.5) which receives signal from the controller (C) is pivotally connected to plurality of pinion (3.3). The microslit assembly (A) and (B) are kept on the respective chemical tank (1). The enlarged view shows that microslit blade (3.1) closes the opening of the chemical tank (1). The plurality of actuator motor (3.5) receive signal from controller (C) and accordingly rotate the plurality of wheel pinion (3.3). The gear arrangement of plurality of pinion (3.3) gives fine tilting movement to microslit blade (3.1) through wheel (3.2) so as to achieve desired opening or closing of the plurality of microslits (3). The microslit assembly (A) and (B) can also be provided with the tilting movement with the use of worm and worm wheel mechanism, rack and pinion mechanism and hydraulic or pneumatic cylinder.

As shown in fig. 6A and 6B, the fabric (10) is rolled over guiding rollers (9). The respective chemical tank (1) is provided with the microslit assembly (A) and (B) at one corner. The plurality of microslit blade (3.1) closes the opening of the chemical tank (1) (Fig. 6A). When the actuator motor (3.5) receives signal from controller (C), according movement is generated with the help of plurality of pinion (3.3) and plurality of wheel (3.2) assembly. The plurality of microslit blade (3.1) receives tilting movement and moves away and thus opening the chemical tank (1) allowing the solution to flow over the fabric (10). The fabric (10) passes over or runs over the tip of the said microslits (3) and comes into the physical contact of the solution flowing. The excess and unused solution is collected back in plurality of overflow tank (5) with the help of plurality of overflow collector sheet (4) (Fig 6B). When the controller (C) gives signal to the plurality of actuator motor (3.5), the actuator motor (3.5) rotates precisely the same amount and turns plurality of pinion (3.3) in clockwise or counter clockwise direction by same precise degree. While the plurality of pinion rotates (3.3) it turns the plurality of wheel (3.2) on the shaft (3.4) and lifts or lowers the microslit blade (3.1) giving upward or downward movement precisely as per the signal from controller (C).

The microslit assembly (A) and (B) can also be provided with the tilting movement with the use of rack and pinion mechanism, ball screw and nut mechanism, crank and crank shaft mechanism, eccentric mechanism, hydraulic or pneumatic cylinder.

As shown in fig 7, microslit blade assembly for sliding movement comprises of microslit blade (3.1), plurality of sliding blade guide (11.1), plurality of housing (11.2), plurality of bush (11.3), plurality of blade shaft (11.4), plurality of connecting piece (11.5) and actuator motor (3.5). Plurality of blade shaft (11.4) is connected with plurality of connecting piece (11.5) wherein the plurality of connecting piece (11.5) has threads which match with threads with the plurality of housing (11.2) The blade guide (11.1) and the housing (11 ,2) are fixed parts and do not move they only guide the blade and the blade shaft. The actuator motor (3.5) is pivotally connected to plurality of blade shaft (11.4) which receives signal from the controller (C). When the signal from controller (C) rotates actuator motor (3.5), it rotates the plurality of blade shaft (11.4) and is guided in plurality of bush (11.3). The blade shaft in turn rotates the connecting piece (11.5). The connecting piece is pushed forward or backward because of matching threads inside the fixed housing (11.2). When the connecting piece moves forward or backward, it moves the blade (3.1) also which is connected with connecting piece. This movement ends up in opening or closing of the respective micro slit.

Referring to fig. 8A and 8B. The fabric (10) is rolled over guiding rollers (9). The respective chemical tank (1) is provided with the microslit assembly (A) and (B) at one corner. The microslit blade (3.1) closes the opening of the chemical tank (1) (Fig. 8A). When the actuator motor (3.5) receives signal from controller (C), according movement is generated as explained above and thus opening the chemical tank (1) allowing the solution to flow over the fabric (10). The fabric (10) passes over or runs over the tip of the said plurality of microslits (3) and comes into the physical contact of the solution flowing. The excess and unused solution is collected in plurality of overflow tank (5) with the help of plurality of overflow collector sheet (4) (Fig 8B).

The microslit assembly (A) and (B) can also be provided with the sliding movement with the use of rack and pinion mechanism, ball screw and nut mechanism, crank and crank shaft mechanism, eccentric mechanism, hydraulic or pneumatic cylinder.

The flow through the microslit blade (3.1) should be pre calibrated on the either plurality of wheel (3.2) and plurality of pinion (3.3) arrangement for proposing tilting movement or plurality of shaft (11.4) proposing sliding movement for different openings and this data is stored in the controller (C).

There is an individual signal for the top and bottom microslit assembly (A and B) sent by controller (C), which may be same or different as per the requirement. In case when the fabric (10) is to be treated only on either side, an according signal is sent by controller (C).

WORKING OF THE INVENTION

In the proposed invention, fabric (10) is guided over the plurality of guiding rollers (9), which are placed apart for the swift movement of the fabric (10). The fabric (10) is stretched horizontally and treated with the help of plurality of the microslit assembly (A) and (B) on the top and on the bottom side. The plurality of microslits (3) is kept throughout the width of the fabric (10) and is provided with the solution from their respective chemical tank (1). The control valve (2) is placed in each of the chemical tank (1), which controls the level of solution in the chemical tank (1). When the plurality of microslits (3) open according to the signal from controller (C), the solution flows through the controlled opening throughout the width of the plurality of micro slit (3). The fabric (10) passes over or runs over the tip of the said plurality of microslits (3) and comes into the physical contact of the solution flowing. The fabric (10) absorbs the solution and gets moist. In case when the width of the fabric (10) is less than the width of the plurality of microslit (3), the excess solution drains or spills over the plurality of overflow sheet (4) and is collected into plurality of overflow tank (5). When the level in the plurality of over flow tank (5) touches the respective plurality of sensor of overflow level controller (6), the pump (7) starts and pushes the solution to the storage tank (not shown in the figure). While the fabric (10) is running over the guiding rollers (9) and the solution flows through the said plurality of microslits (3), the level in the chemical tank (1) gradually decreases. The plurality of level controlling sensor (8) senses the level and controls the level of the solution in the plurality of chemical tank (1) through level controller (not shown in fig.). The plurality of level controlling sensor (8) helps the plurality of chemical tank (1) to maintain required level of the solution through the plurality of control valve (2) receiving the solution from the storage tank (not shown in fig.) The plurality of level controlling sensor (8) can be of on/off type or PID type preferably of PID type level controlling sensor that provides precise results.

The desired opening and closing of the said plurality of microslit (3) is achieved by controller (C). The controller (C) is provided with inputs such as weight of fabric in GSM (grams per square meter) and moisture or solution to be applied to the fabric as percentage. When the textile machine starts, an according input signal from the machine drive motor (to which the microslit padder is attached, not shown in fig.) is fed to the controller (C). Moreover, continuous feedback of the fabric speed is taken as input. The solution requirement is calculated by controller (C) in the following way:

Fabric weight in grams (per meter width of fabric) passing over the microslit every minute = GSM (Input) X speed of the machine in meters per minute (from signal)

Requirement of the solution in grams per meter width per minute = the fabric weight X percentage of moisture (input)

The controller (C) takes the value of GSM and percentage as input fed externally fed by the user and takes the signal of machine speed from the main machine drive and thus calculates the requirement of the solution in lit/min.

The flow through the plurality of microslit blade (3.1) should be pre calibrated on the either plurality of wheel (3.2) and plurality of pinion (3.3) arrangement for proposing tilting movement or plurality of shaft (11.4) proposing sliding movement for different openings according to pre calculated data as stored in the controller (C).

Based on the above data, the opening of the plurality of microslit (3) is calculated by the controller (C) and according signal is given to actuator motor (3.5) of the microslit assembly (A and B) that proposes accurate opening or closing of microslit blade (3.1). There is an individual signal for the top and bottom microslit assembly (A and B), which may be same or different as per the requirement. In case when the fabric (10) is to be treated only on either side, an according signal is sent by controller (C).

When the fabric speed is increased or decreased, controller (C) gets a signal from the main machine drive (not shown in fig.) and opens or closes the plurality of micro slit blade (3.1) by sending signal to plurality of actuator motor (3.5). This allows only required solution to flow through the opening and thus automatically controls the amount i.e. the percentage of moisture (solution) on the fabric (10). The operation and equipments are same for both top and bottom side of the fabric (10). However the data input can be different and hence the amount of solution can also be different for both top and bottom side of the fabric (10).

Manual over ride also is possible by the user. Manual over ride gives a "shift" to complete base line so that moisture content can be increased or reduced compared to set value.

With this treatment, the fabric (10) contains around 30% of moisture which is sufficient for carrying the chemicals and spreading evenly all over the fabric (10). This moisture content of 30% is nearly half of achievable by the any of the existing inventions which is normally 55% to 60%. The fabric (10) is further passed through any of known heating process so that excess humidity can be removed and also helping in chemical reaction also.

As the fabric (10) is provided with the solution in required amount only, the load on drying process is significantly minimized. Thus the present invention saves significant amount of water and energy. The present invention also becomes efficient by saving time to finish the fabric (10).