BR102019007130A2 - STEAMING AND SOFTENING PROCESS AS WELL AS CLARIFICATION AND CLEANING OF JEANS TISSUE IN OZONE GENERATOR CHAMBER, COMBINED WITH STONING STEPS, RINSES, CENTRIFUGATION, DRYING AND LASER RAY EFFECTS - Google Patents

Abstract

eliminated the use of water in the degumming stage, and in the stages of whitening and cleaning jeans garments (2), as well as in the stage of producing vintage effects in indigo, thereby reducing the softness achieved in the initial stage. use of water for the steps of estonagem and rinse. for that, the garments (2) are degummed in the chamber of an ozone gas generator (1). given the softness initially obtained in the washing and rinsing stages in the washer (3), the water ratio for each kg of parts (2) is substantially lower. the laser treatment in the laser equipment (4) is also done without the use of water, as well as the bleaching and cleaning step, which is done in the ozone generator chamber (1). the final step of three rinses is also done at a substantially lower water ratio for each kg of parts (2). therefore, by the proposed process, an average of 80% of the volume of water (which is captured and reused) is eliminated, a reduction of up to 30% of steam and wood used in the boiler, bringing 50% of electricity savings. in addition, chemical products are not used, avoiding the occurrence of residues and contaminants, and ozone gas, natural is 100% ecological, decomposing into oxygen.

Description

STEAMING AND SOFTENING PROCESS AS WELL AS CLARIFICATION AND CLEANING OF JEANS TISSUE IN OZONE GENERATOR CHAMBER, COMBINED WITH STONING STEPS, RINSES, CENTRIFUGATION, DRYING AND LASER RAY EFFECTS

[001] The present specification refers to a patent application for a method of preparing garments such as jeans and other pieces that use similar fabric for their manufacture, where, in a ozone chamber, through specific techniques in its interior, in a short period there is a process that allows to soften the fabric, that is, to ungain the jeans making them soft using only ozone gas.

[002] Through this process, the softness and disinfection initially obtained help to reduce water consumption in the following steps, eliminating the use of chemicals. Therefore, the garment goes through a stage of stoning with less water, centrifugation and drying, followed by the use of laser equipment, without the use of water, to receive visual effects such as mustache, sanding, points of light and the frayed effect, among other transformations that exposure to the incidence of these laser rays provide. The garments thus treated return for another passage in the ozone chamber for clarification and cleaning, also without using water, followed by washing with less water, centrifugation and drying, to finally be packed and delivered to the consumer market.

Technique Comments

[003] As we know, nowadays it is very common to look for customized clothing mainly by the youngest, wanting to purchase clothing such as, for example, jeans differentiated by their own effects and designs that make them personalized. For this process, the industry uses several steps for this customization, such as steps in mechanized systems that print the image at high temperatures, and sanding processes and, final finishing steps which make use of chemicals, for the whitening of the fabric

[004] As you know, there are currently several types of treatment (processing) of fabrics such as "jeans".

[005] Just as an example, the patent document PI 0700942-9 of 2007 called “PROCESS FOR THE REVELATION OF DESIGNS WITH RELIEF IN JEANS FABRICS OR CLOTHES THROUGH GOUFRAGING AND POSSESSION OF DRAINING, CORROSION AND DEFINING OF DYES AND FIBERS OF JEANS IN THE WASHING STEP ”. This process cited as an example of the state of the art protects the introduction of the fabric in a rotating calender with cylinders with relief designs, being engraved by grouping, through high temperature produced by electrical resistances. Then the textile piece undergoes abrasion at the engraving site and proceeds to the conventional washing step, keeping the design in high relief on the jeans exposed.

[006] In any case, the conventional washing of jeans is usually done in industrial washing machines, centrifuges and the like, some working under high temperatures.

[007] The washing can be done with corrosive chemicals to leave, in the middle of the water volume, “tears” in the pieces, showing the contrast of the blue of the warp threads with the white threads of the weft. Another type of washing ("estonado") uses volcanic stones, light and porous, hit in the washing machine together with the water leaving uneven grooves in the fabric. The fabric itself already "stoned", after ready can receive gray dyes, or, on the contrary, bleaching solutions as well as undergoing retention to achieve a different color. This retained fabric can still be washed again.

[008] A fade wash can be done before the garment is made, using bleaches and chemical enzymes that completely and uniformly fade the jeans. This fading can be done after the garment is made, being a fading called “délavé”. These faded “délavé” jeans can also receive high-density chemical bleaches, giving the garment a wear and aging effect in light jeans. Jeans that have a medium stoned base can be overcoated with khaki, also giving them an aging effect or also be washed with random splashes of corrosive chemical material that whitens the finished piece, as if they were snowflakes.

[009] Another type of washing (“distressed medium”) is done in dark jeans with prior softening, going through the manual sanding step.

[010] Jeans can be covered (“coated”) with resin and pigment, in metallic color, silver or gold.

[011] Washing can cause localized wrinkles, over-dyeing with different shades of dyes, creating greenish, violet or yellowish dirt effects, frontal wear on the front, stains with brushes or ink jets, graphite, in addition to prints simulating corrosion. These effects give the jeans a worn or worn look.

[012] Dark jeans (indigo or black) can be washed with red dyes, with green overcoat (camouflage effect).

[013] Anyway, a major problem observed in these types of known improvements mentioned above, is that these industrial washing machines require extremely high volumes of water and consequent energy consumption since they work for long cycles for processing. In addition, there is a need for the massive use of stones (washing with pumice stones) and other chemical agents and additives as elements for abrasion, wear and dyeing.

[014] The use of pumice stones, for example, requires that its remains be removed manually from the treated garment, as they can impregnate in the pockets, in the folds, in addition to causing clogging in the washing machines or even damage to the electric motor of the equipment.

[015] Cellulases-like enzymes can be used alternatively in these processes of improvement of the textile industry as they are capable of breaking cellulose in the fabrics, causing fading. However, they accelerated abrasion, which can cause wear on washing machines and generate environmental problems as they are not easily biodegradable.

Patent Objective

[016] The process in question, which is the reason for this patent application, is a process for treating jeans-type garments using only (purely) ozone gas, for degreasing the fabric and oxidizing the dyeing combined with steps of stoning, and using laser equipment for stamping and visual creation, with washing and centrifugation steps, to obtain the numerous desired effects mentioned in the technique.

[017] Therefore, after numerous researches in this textile field, through the process in question the use of chemicals with water reduction of up to 80% is avoided and their reuse, reduction of energy consumption, speed, preservation of the environment and protection operators' health.

[018] Explained superficially, the process starts to be better detailed through the sequence of figure 1, described below, and figure 2:

[019] Figure 1 - shows schematically, by arrows, indicating the sequence of the process, where the garment (in the case shown, jeans) is taken to the chamber of an ozone generator for the initial “degumming” stage under direct reaction of ozone, being then transferred to an industrial washing machine for the “estonagem” stage or aging effect through biological enzymes, being rinsed with the minimum amount of water and then centrifuged and dried. In this condition, the garment goes to a laser machine to receive the incidence of the rays that will, by logical programming, produce the desired effects on the fabric. As shown by the return arrows, the garment is taken back to the ozone gas chamber for the bleaching and cleaning step without using water and then taken to the industrial washer for washing, rinsing, with little water, centrifugation. and drying, finally being transferred to the ironing, overhaul and packaging sector to supply the market;

[020] Figure 2 - shows, for illustrative purposes, a garment, in this case jeans treated according to figure 1, after being removed from the industrial washing machine, at the end of the process.

[021] In accordance with the schematic sequence of figure 1, the “DEGREASING AND SOFTENING PROCESS AS WELL WHITENING AND CLEANING JEANS IN OZONE GENERATOR CHAMBER, COMBINED WITH STONING, RINSE, STAINING, DRYING AND EFFECT STAGES LASER ”, object of this present invention patent application, consists of industrial procedures totally devoid of the use of chemical products, thus preserving the environment and also the health of operators, starting from the first stage, occurred more precisely in an ozone gas generator chamber (1) (produced by breaking and regrouping oxygen between two electrodes under high voltage of large electrical discharges such as 15,000 volts or more), where pieces of clothing are introduced (2) or preferably pieces of jeans, indigo fabric, raw. During a specific period of 10 minutes, this strongly oxidizing gas causes a reaction with the starch of the fabric gum, breaking its molecules and giving it a soft touch or “degumming” (the gum or resin is applied to protect the fibers during the mechanical process of weaving). This step, as a novelty for the process, is definitive because water is not used, but must be combined, however, with subsequent steps described below.

[022] After this period of 10 minutes under the action of ozone gas, the garments (2) are already degummed and, due to the softness acquired initially, favor the subsequent treatment because, when taken to an industrial washing machine (3), require less volume of water when going through the stage of estonagem, where, for 30 to 60 minutes, amid biological enzymes the water ratio is 3 liters for each kilo of garments (2), giving the fabric the effect of wear, this step ended with rinsing, in a quantity of water also with a lower volume, in a water ratio of 10 liters for each Kg of garments (2). After being centrifuged and dried, the garments (2) go to laser equipment (4) where, according to files received by the logical programming (PL), the desired designs are reproduced with the burning of the fiber surface by the incidence of laser rays, causing visual effects such as "whiskers", sanding, light spots, frayed portions, among other effects, avoiding sanding, spraying with chemicals and, equally at the initial stage, the use of water.

[023] After the desired effect is fixed, the garments (2) are returned to the ozone gas generator chamber (1) so that, once again under the action of only this fluid, they are cleared and cleaned also without the use of water.

[024] Finally, returning to the industrial washing machine (3) the garments (2) go through three rinses in the ratio of 10 liters of water for each Kg of pieces (2), which are then centrifuged and dried and, in this condition, already ready, as shown in figure 2, they are taken to the ironing section, undergoing a review and packaging step, so treated, to be supplied to the consuming public.

[025] As can be seen, when the degumming, whitening and final cleaning steps are carried out by ozone gas, as well as the effects are applied by laser equipment, the water used is restricted to the step of stoning and rinsing, even so, requiring lower volume thanks to more effective initial softening (by ozone gas). The laser process also eliminates the need for water. Therefore, an average of 80% of the volume of the precious natural liquid normally used is eliminated, with the right to capture and reuse by the industrial washer system itself. In addition, in the industrial laundry boiler, a reduction of up to 30% in steam and wood is obtained, bringing, at the end of the process, 50% of electricity savings.

[026] According to the process proposal, for the degumming, whitening and cleaning step (by ozone gas), for the estonage step (with biological enzymes) and for the effects production step (by laser equipment) , chemicals are not used, preventing the occurrence of residues and contaminants.

[027] The ozone gas itself contributes towards being a 100% ecological natural gas, decomposes into oxygen without generating toxic by-products, in addition to disinfecting the tissue of contaminating microorganisms with great efficiency.

Claims (1)

“PROCEDURE FOR DEGREASING AND SOFTENING AS WELL AS CLARIFICATION AND CLEANING OF JEANS TISSUE IN OZONE GENERATOR CHAMBER, COMBINED WITH STONING STEPS, RINSES, CENTRIFUGING, DRYING AND EFFECTS BY LASER RAY”, constituted by the use of the generator of the chamber using ozone gas (1), recipient of the introduction of denim garments (2), indigo fabric, raw, which are characterized by exposure to the direct incidence of ozone gas for 10 minutes for the degumming step (in reaction of this fluid to the breakdown of starch molecules from tissue gum); followed by a stage of stoning between 30 to 60 minutes in a washing machine (3), in a ratio of 3 liters of water (containing biological enzymes) for each kg of garments (2); step of rinsing the garments (2) in the washing machine (3) in a ratio of 10 liters of water for each Kg of garments (2); centrifugation and drying steps; treatment stage in laser equipment (4) to produce effects on the tissue under the action of laser rays; whitening and cleaning stage with the return of the garments (2) already treated, to the ozone gas generator chamber (1); step of three rinses in the washing machine (1) in a ratio of 10 liters of water for each Kg of garments (2); centrifugation and drying steps; ironing steps followed by a review step and a packaging step.

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