US20160305056A1

US20160305056A1 - Centrifugal dyeing apparatus for treating wound fabrics

Info

Publication number: US20160305056A1
Application number: US15/103,212
Authority: US
Inventors: Thomas Widmer; Thomas Gerhard
Original assignee: LAB-PRO GmbH
Current assignee: LAB-PRO GmbH
Priority date: 2013-12-09
Filing date: 2014-12-04
Publication date: 2016-10-20
Also published as: WO2015086163A1; CH708107B1; EP3080347A1; CN105814250A

Abstract

An apparatus to treat wound sheet forms, especially textile sheets, with fluids is provided. The treatment includes the bleaching, the dyeing, and the washing of knitted and woven textile and fleece. Such sheet forms may include any of cellulosic, animal, and synthetic fabric and their compositions. The sheet forms wound onto a perforated dyeing beam are treated with the fluids by means of centrifugal force in such a way that a regular treatment with the least use of water, chemicals, and energy is possible. A centrifugal dyeing apparatus includes a closable container, a pump to circulate a treating fluid, a driven dyeing beam, which is rotatably supported in the container, arranged to hold a lap made of a textile sheet form and having a tube with a perforation, wherein support sustainers are provided, wherein the support sustainers radially support the lap, and wherein the support sustainers (6) are attached to the dyeing beam.

Description

FIELD OF THE INVENTION

The present invention relates to a centrifugal dyeing apparatus for treating wound sheet forms, especially textile sheets, with fluids. The treatments comprise the bleaching, dyeing, and washing of knitted and woven textile as well as fleece. These sheet forms can comprise any of cellulosic, animal, and synthetic fabric and their combinations. Wound onto a dyeing beam, the sheet forms are treated with fluids by means of the centrifugal force in such a way that a regular treatment with the least consumption of water, chemicals, and energy is possible.

BACKGROUND OF THE INVENTION AND RELATED ART

Textile sheet forms are treated on machines and apparatuses with many different processes to provide them with different qualities such as color, shine, softness, etc. All widespread processes and their appendant machines and apparatuses have in common that they cause a consumption of water, chemicals, and energy. As a replacement of water and, therefore, for a waterless operation, supercritical carbon dioxide (CO₂) has not widely established itself, probably because of the tremendous technical effort. Nevertheless, it may be interesting to apply the present invention in the future also for processes with CO₂.
The wastewater resulting from the treatment process has to be cleared in wastewater treatment plants because otherwise bodies of water are polluted. Consumption of water, chemicals, and energy is very different with respect to the processes and the applied machines and apparatuses. Therefore, the costs are also very different with respect to the composition of the water, chemical, personal, and energy costs. Besides the costs, the quality of the treatment result is a criterion for the selection of the process as well as the machines and the apparatuses.
Dependent on the selected process, the machine, and the apparatus as well as the qualities of the textile sheet form to be treated, such as elasticity, ability to shrink under the influence of temperature, etc., it is to some extent difficult to treat the textile sheet in such a way that the qualitative result of the treatment is proper with respect to color, surface hairiness, dimensional accuracy, etc.
It is known that textile fabrics are treated with discontinuous processes on jet dyeing machines, dyeing beam apparatuses, and jiggers. Also known are continuous processes and their apparatuses, such as continuous bleaching or dyeing apparatuses. Further, the processes are applied in various combinations to achieve qualitatively proper results with preferably low costs.
In these discontinuous processes and these associated machines and apparatuses, the liquor ratio, having the unit dimension liter per kilogram goods to be treated, is an important parameter, which significantly affects consumption of water, chemicals, and energy. The bath ratio is defined as the minimum amount, in liters, of water needed divided by the mass of textile goods to be treated in the machine or the apparatus. The whole process is a combination of several individual process steps. Because the total consumption is the sum of the consumptions of the individual process steps, it is important, in view of economical and ecological reasons, that the bath ratio of a discontinuous dyeing machine or apparatus is as low as possible.
Known discontinuously working machines, such as jet dyeing machines or dyeing beam machines, normally work with bath ratios which are greater than 3 liter per kilogram goods, typically between 4 and 20 liter per kilogram goods, when cellulose sheet forms are treated; and greater than 2 liter per kilogram, typically between 3 and 20 liter per kilogram, for synthetic fibers.
With jiggers, a treatment with lower bath ratios is possible with a full load and with optimized processes. But the jigger is only eligible for tensile insensitive sheet forms because tensile sensitive sheet forms would be elongated under the influence of the garment's tension which is necessary for jiggering. However, this elongation is generally undesirable because it can only partially be removed. Also, the process time is longer than on jet dyeing apparatuses, especially with large fabric lengths.
Due to a good compromise of flexibility, consumption, quality, and process time, today, the jet dyeing machine is probably the most used discontinuous dyeing machine for knitted textiles. For woven textiles, both the jet dyeing machine and the jigger are commonly used. In consequence of the poor bath ratio and the therewith increased process costs, beam dyeing apparatuses are mostly used only in case that qualitative problems with the sheet forms to be treated arise on jet dyeing machines or jiggers.
A simplified, yet very typical process, in which knitted textile made of cotton is bleached and dyed on a jet dyeing machine, follows.

1.) Filling: 5 liter water per kilogram goods
2.) Bleaching: (loading chemicals, heating, and cooling again)
3.) Discharging, rinsing: 2.5 liter per kilogram goods
4.) Discharging, rinsing: 2.5 liter per kilogram goods
5.) Discharging, filling: 2.5 liter per kilogram goods
6.) Dyeing: (adding salt, dye, and chemicals and heating)
7.) Discharging five times: 12.5 liter per kilogram goods
8.) Discharging.

A total of 25 liter of water per goods is used in this exemplary process. 17.5 liter water per kilogram goods and therefore 70% of the total water consumption is used to cleanse.
As can be seen above, the first filling is 5 liter water per kilogram goods. Approximately 2.5 liter water per kilogram goods is sucked up by the fabric. The second 2.5 liter water per kilogram goods is needed for the machine because pipes, a pump, and a heat exchanger must be filled to enable a continuous circulation. When thereafter the machine is discharged, 2.5 liter per kilogram goods leave the machine. The remaining 2.5 liter per kilogram goods stay in the goods and therefore in the machine. Therefore, in per cent of the goods weight, 250% water stay in the goods. These 250% are called water retention value, and it is mainly dependent on the fiber type.
As shown above, 70% of the water consumption is used up for rinsing. If the retaining power were reduced by 50%, the water consumption would be reduced by 35%. The reason for this is that rinsing is a dilution process, and when only 50% of the dirty water has to be diluted, then also only 50% of the clean water is needed to achieve the same effect.
Because the retaining power is yet determined by the fiber type, a reduction of the retaining power is not directly possible. If the water were yet efficiently removed, this would equal a reduction of the retaining power because less dirty water must be diluted.
To save chemicals, primarily the bath ratio has to be reduced because the chemicals are employed for the most part in process steps, such as bleaching and dyeing. Most chemicals, such as hydrogen peroxide and caustic, are deployed in milliliter or gram for each liter of water so that the amount of chemicals used can be reduced at lower bath ratios. Based on the above example with a bath ratio of 5 liter water per kilogram goods, the amount of chemicals could be reduced, as an example, by 50% at a bath ratio of 2.5 liter water per kilogram goods.
A very widely spread process is the dyeing of goods made of cellulose material, like cotton or viscose, with a reactive dye. In this process, large quantities of salt are used. The salt has the function to increase the effect of the dye. Not applying the salt, only a small part of the dye would engage in chemical bonding with the fiber. The consumption of dye would be higher, and the unbound part would demand more water to be washed out.
In processes with reactive dyes, an amount of salt between 20 and 150 gram per liter water is common. At lower bath ratios, the amount of salt per liter water can be reduced. Hence, one has a double effect. If the bath ratio can be cut in half, then the total amount of salt can be reduced to less than the half.
Further, it is widely known that the water consumption in rinsing operations can be drastically reduced when the goods are drained before by centrifugal forces. This process is performed in every household's conventional laundry machine.
From U.S. Pat. No. 1,195,606 it is already known that textile sheet forms can be successfully treated with centrifugal forces. Though, it is stated that the sheet form must be wound with high tension. Sheet forms which are tension sensitive, such as knitted textile and longitudinal elastic woven textile, however, should not be wound with high tension because, then, the sheet form degrades in elasticity.
DE 1760778 discloses that it was possible to successfully dye small amounts (between 2 and 3.5 kg) of woven nylon textile. The described woven textile is practically inelastic so that it could be successfully treated with the described number of revolutions and, therefore, with centrifugal forces.
For longitudinal elastic, textile sheet forms, such as knitted textile, with or without a spandex component, and woven textile with an elastic warp, such a procedure is impossible because the centrifugal force stretches the sheet form longitudinal and imbalances are generated which can damage both the textile sheet form and the machine. Also with textile sheet forms having a voluminous, soft character, imbalances are generated so that a treatment as described above is impossible.
Also known are dyeing beam apparatuses that have a lap which is rotated. Yet, that is done with a relatively moderate rotational speed so that, as common for beam dyeing, the treatment fluid is pressed through the lap with pump pressure and not, as described above, by means of the centrifugal force. Therefore, the interior volume of the dyeing beam is completely filled with the treating fluid. Especially for large diameters of a dyeing beam, this increases the amount of the treating liquor per kilogram goods. The apparatuses described in U.S. Pat. No. 1,195,606, U.S. Pat. No. 1,261,500, U.S. Pat. No. 1,261,501, and U.S. Pat. No. 1,266,110 also have this disadvantage because the interior volumes of their dyeing beams also must be filled.
A partial improvement with respect to a lower bath ratio is achieved with displacement bodies located in the interior of the dyeing beam, as described in EP 0230630. Further, it is known that the fluid level in the container can be lowered for beam dyeing apparatuses that have a lap which is rotated so that therewith also a partial improvement is achieved.
It is known from beam dyeing that unstable laps are wound with an inelastic sheet. Therefore, the circumference of the lap is stabilized. That means that the circumference of the lap is no longer able to increase in length because of the sheet wound around the lap. Experiments have shown that wrapping a preferably inelastic sheet around longitudinal elastic and voluminous sheet forms yields a certain improvement, but does not suffice to avoid asymmetric displacements in the lap. Such displacement grows in size the softer the leap and the larger the layer thickness. Such asymmetric displacements create pressure points on the sheet form as well as forceful imbalances and therefore vibrations in the whole machine.
Also chain forms, as known from U.S. Pat. No. 1,261,500, U.S. Pat. No. 1,261,501, and U.S. Pat. No. 1,266,110, are not able to avoid such asymmetric displacement. The circumference of the lap is held fixed through this chain form. The chain form yet cannot avoid that the lap, especially if it is soft, is pressed on one side and, therefore, suffers an extension on the other side so that the rounded lap is formed into an asymmetric form. If they are not very fine, such chain forms further have the bad quality that their raisings and lowerings are impressed into the outer layers of the lap through the pressure created by centrifugal forces. Consequences of this are irregular treatments and, therefore, color differences.
Large layer thicknesses are yet relevant for economical reasons because with small layer thicknesses less sheet forms are treated and, therefore, the apparatus produces less. High revolution speeds are advantageous because the lap body can be better drained with high revolutions, and, therefore, as already stated above, rinsing water can be saved.

OBJECTS AND SUMMARY OF THE INVENTION

In view of the described state of the art, an object of the present invention is to treat wound sheet forms, notably also elastic or soft sheet forms, which are wound onto a perforated dyeing beam with solutions by means of centrifugal forces in such a way that a regular treatment is possible at large layer thicknesses and with the least consumption of water, chemicals, and energy.
This object is solved according to the present invention by a centrifugal dyeing apparatus comprising a closable container, a pump to circulate a treating liquid, a driven dyeing beam, which is rotatably supported in said container, arranged to hold a lap made of a textile sheet form and comprising a tube with a perforation, wherein support sustainers are provided, wherein said support sustainers radially support said lap, and wherein said support sustainers are attached to said dyeing beam.
In an advantageous way, it is proposed that support sustainers are provided, that the support sustainers radially support the lap, and that the support sustainers are attached to the dyeing beam so as to achieve that the lap cannot radially extend itself during the following treatments under the influence of centrifugal forces and the treating float passing through the sheet form during the following treatments. Further, the apparatus should prevent asymmetric displacements in the lap so that imbalances cannot occur. Hereby, the support sustainers radially support the lap during operation.
It is advantageous that the support sustainers are arranged coaxially to the dyeing beam. Because the support sustainers undergo high forces due to the centrifugal force, it is advantageous that they are as short as possible. As a result of the coaxial arrangement, the shortest way across the sheet form is achieved.
Further, it is advantageous if the support sustainers are made of closed hollow profiles. Closed hollow profiles have a very good bending strength as well as simultaneously a small (low) mass. Furthermore, the profiles can be closed also at their sides so that a treating float cannot enter into the profiles, and, hence, they are also easy to clean.
The sheet forms are treated in different lengths on the centrifugal dyeing apparatus. The sheet forms further have different thicknesses. The thicknesses after wrapping are therefore mostly different so that it is advantageous if the support sustainers are movable to enable an adjustment to the thickness of the lap. It is advantageous that the support sustainers are arranged alongside the entire width of the lap (goods) because the centrifugal force also acts on the lap over the entire width of the goods. Especially for elastic goods and an only partial covering of them, the lap would extend itself at uncovered sections.
Further, it is advantageous that perforated metal sheets, which serve as perforated support sheets, are mounted on the support sustainer and that they lie against the lap. The perforated metal sheets receive the pressure over a large area so that less impressions from the support sustainers are created on the goods. Further, the perforated metal sheets can overlap each other so that the same metal sheets can be used for various lap diameters.
For inelastic goods, it is advantageous that the perforated metal sheets cover at least 10% of the circumference of the lap and the whole width of the lap. The reason for this is that large parts of the centrifugal force are carried through the inherent stability of the lap. Because, despite that, imbalances can occur, it is advantageous that the lap is supported along at least 10% of the circumference of the lap over the whole width of the lap.
It is notably advantageous that the support sustainers and the support sheets together form a unit. By combining them to a unit, weight can be saved so that less energy is needed to speed up the lap. In addition, the support sustainers must be mounted onto the dyeing beam by operators. Hence, for this, a low self-weight is also advantageous.
An economically priced solution is that the support sustainers are mounted, favorably on the left and right side of the lap, through support sustainer fixtures at unperforated regions of the tube of the dyeing beam. The reason for this is that, then, the support sustainers can be formed as short as possible. Then, the support sustainers are only a little longer than the maximum width of the lap so that they can be optimally formed with respect to strength.
An advantageous variant for the mounting of the support sustainers on the dyeing beam is that the support sustainers are mounted at unperforated regions of the tube of the dyeing beam through screws. The mounting with screws enables that the support sustainers are steplessly adaptable to the layer thickness. Yet the screws have to be locked so that they cannot release themselves during operation.
It is advantageous that the dyeing beam comprises side plates that are connected with the tube. Because of the centrifugal force, it must be possible to transfer substantial forces into the dyeing beam through the support sustainers and their support sustainer fixtures. The support sustainer fixtures transfer the forces on the left and the right of the lap and, therefore, at the sides of the dyeing beam. The side plates optimally strengthen the tube.
It is advantageous that the support sustainers are mounted to the side plates of the dyeing beam through the support sustainer fixtures. Therefore, there are no parts which spread out from the dyeing beam so that the sheet form can be wound without difficulty onto the dyeing beam.
A solution which is advantageous for the operators is that the support sustainer fixtures are turnably mounted at the side plates and that the positions of the support sustainer fixtures can be locked by means of spring bolts. This solution does not need tools to connect the support sustainer fixtures with the dyeing beam. The number of parts which the operator has to mount is thus reduced to that of the support sustainers equipped with the perforated metal sheets so that the operator could make fewer mistakes when mounting the means.
Another advantageous variant consists in that the support sustainers are mounted with screws and bolts at the side plates, preferably at two side plates, of the dyeing beam. This solution, which is based on standard parts, is both economically desired as well as steplessly adaptable to the thickness of the lap and, through directly connecting with the stable side plates, robust. As already mentioned above, screws and screw nuts must yet be locked against turning to prohibit an unwanted loosening during the treatment.
Especially for broad sheet forms the support sustainers become very long and can elastically deform themselves during the treatment. Therefore, it is advantageous that at least a strap is applied around the support sustainers and the lap. The strap strengthens the support sustainers and reduces the elastic deformation during the treatment. Further, by applying there one or more such straps, the bending strength of the support sustainer can be reduced, and, therefore, weights and costs of the support sustainers can be reduced.
As already mentioned above, the laps have different layer thicknesses, and the support sustainers thus have to be radially adjustable. Therefore, it is advantageous that the at least one strap is adjustable in length because otherwise straps must be provided in most different lengths.
It is advantageous that the container is provided in the form of a pressure vessel. Indeed, it is possible to install the centrifugal dyeing apparatus without a pressure vessel, which is considerably cheaper. Providing the container as a pressure vessel has the advantage that cellulose and synthetic fiber material sheet forms can both be treated on the same apparatus. Further, the treatment duration can be reduced for a bleaching process for cellulose sheet forms, when the treatment is performed at temperatures over 100° C. and, therefore, under pressure.
Yet it is possible that the dyeing beam stays in the centrifugal dyeing apparatus during wrapping. This is possible for both centrifugal dyeing apparatuses without pressurized containers and such apparatuses with pressure vessels. Centrifugal dyeing apparatuses with pressure vessels in which the dyeing beam stays in the apparatus during wrapping are considerably more complex to build because, to wrap the dyeing beam, it must be accessible over the entire width of the goods, and the cylindrical part of the pressure vessel thus must be arranged to be laterally movable. Therefore, it is advantageous that the dyeing beam can be removed from the container.
It is advantageous that the centrifugal dyeing apparatus comprises a spraying tube that is arranged centrically to the dyeing beam. For highly permeable sheet forms or high numbers of revolutions, no liquid layer builds up inside the dyeing beam. The treatment float must thus be provided as much as possible regularly along the entire width of the lap because otherwise it differently passes the lap along its width. Without a spraying tube, this would result in an irregular treatment result.
It is advantageous that watery solutions and/or a solvent and/or carbon dioxide (CO₂) in a supercritical state is used as a treating float. In a lot of textile finishing processes, watery solutions are used. Also solvents are used to remove grease and/or oil. Obviously, an apparatus operating with solvents requires further components according to the state of the art, such as an exhaust system and devices which clean the solvent. Yet the washing process is here also a dilution process so that similar savings as with watery solutions are possible. Dependent on the availability of water, in the near future, it could be interesting to replace water with supercritical CO₂so as to transport the dye to the fiber. Hence, preferably, the centrifugal dyeing apparatus and, especially, the closable container and the further components are respectively adapted in such a way that watery solutions and/or a solvent and/or CO₂in a supercritical state can be used as a treating float that transports the dye to the fibers of the lap.
With the mentioned apparatuses, therefore, sheet forms being sensitive to longitudinal tension can be treated which would not be possible without such an apparatus. Furthermore, this has the advantage that laps with much larger layer thicknesses could be treated so that the capacity of the machine can be increased. Through the radial support, the number of revolutions of the dyeing beam can be increased so that, if necessary, the flow passing through the lap can be increased. Also the number of revolutions to centrifuge the lap before rinsing can be increased so that less waste water remains in the lap, and rinsing water can thus be saved.
Table 1 below shows the influence of the centrifugal force on the water remaining in the lap, wherein it has to be considered that, due to the various textile sheet forms and their different qualities, also, the water remaining in the lap considerably varies. The main influence has certainly the fiber material, which is tabulated in column 1. Yet, even with the same fiber material, very large differences are discoverable. So, with polyester, the water remaining in the lap can differ by a factor of 2. This is the case if, for example, a closely woven textile made of polyester filament and a loosely knitted hosiery made of polyester staple fibers are compared with each other. The quality of being closely woven means herein that a certain tightness against water and air is provided. This is the case, for example, for a not much permeable canvas. Hosiery is a knitted textile, wherein due to the meshes a deformation occurs in a longitudinal or transverse direction according to respective tensile loads. A woven textile is stiffer because a relatively tight arrangement of one fiber next to another exists due to the weaving. In Table 1, large ranges, here stated in percent (%), result from these different constructs, which include, besides others, knitted and woven textiles.
It is evident from Table 1 that independent of the type of fiber, the stronger one centrifuges, the less water remains in the sheet form. Therefore, less water is needed for the succeeding rinsing.

TABLE 1

Type of	Dripping (1 g)	2-5 g	5-30 g/	900 g
Fiber	1-2 min.	1-2 min.	1-2 min.	20 min.

Cotton	250-300%	180-240%	80-150%	43-50%
Wool	230-300%	160-210%	80-120%	38-45%
Polyester	120-250%	90-140%	40-80%	3-5%
Viscose	300-350%	200-250%	120-160%	60-80%

In Table 1, the reference quantity g=9.81 m/s²is chosen for the acceleration through the centrifugal force. In column 1, the different fiber types are shown. In columns 2 to 4, the different processes and according machines and apparatuses are contrasted. For the purpose of information, in column 5, the values which are achieved by centrifuging according to ISO 53814 are shown. Thereby, the values shown in column 5 advert to the influence of an acceleration of 900 g on the respective sheet form over a duration of 20 minutes.
For dripping (at 1 g) between 1 and 2 minutes, as shown in column 2, it is noted that, with today's widespread machines, like jet dyeing machines, beam dyeing machines, or jiggers, the sheet form is only drained by dripping so that large quantities of water remain in the sheet form.
For centrifugal dyeing machines without supporters at 2 to 5 g over between 1 to 2 minutes, as shown in column 3, it is noted that, for tension stable garments which are wound with large tension, centrifuging them without supporters is possible. Many sheet forms, such as knitted textile, are yet longitudinal elastic in such a way that the textile is damaged or imbalances occur, already, for acceleration values between 1 and 2 g. In these cases, the dyeing beam without supporters can only be rotated very slowly. In this case, the drainage through the centrifugal forces is only very moderate.
For centrifugal dyeing machines with supporters at 5 to 30 g over between 1 to 2 minutes, as shown in column 4, it is noted that the acceleration values of 5 to 30 g can be realized without difficulty with the centrifugal dyeing beam of the present invention. In principle, also higher acceleration values can be reached. But the number and stability of the supporters must be adapted therefore.
When constructing the supporters, yet it has to be considered that for high acceleration values the mass of the supporter must be included in the calculation because besides the stability of the supporter, also the mass of the supporter is a significant factor. A low mass of the supporters is thus desired.
With the centrifugal dyeing apparatus according to the present invention, a realization of treatments with bath ratios of less than 3 liter water per kilogram sheet form for cellulose fiber and less than 2 liter water per kilogram sheet form for synthetic fiber is possible.
Below, as an example, a process is shown in which elastic knitted textile made of cotton is treated on a dyeing apparatus according to the present invention. Each of the sheet forms is drained over 2 minutes before the rinsing.

1.) Filling: 3 liter water per kilogram goods
2.) Bleaching: (loading chemicals, heating, and cooling again)
3.) Discharging, centrifuging, and rinsing: 1.5 liter per kilogram goods
4.) Discharging, centrifuging, and rinsing: 1.5 liter per kilogram goods
5.) Discharging, centrifuging, and filling: 1.5 liter per kilogram goods
6.) Dyeing: (adding salt, dye, and chemicals and heating)
7.) Five times both discharging and rinsing: 7.5 liter per kilogram goods
8.) Discharging.

In total, 15 liter water per kilogram goods are consumed in this exemplary process. Comparing the above mentioned process performed on the centrifugal dyeing apparatus with the previous, exemplary process performed on a jet dyeing machine, thus it is shown that 10 liter water per kilogram goods and, therefore, 40% of the water can be saved.
Comparable savings are achieved for the amounts of chemicals and salt. Also the energy consumption to heat the process water is reduced by 40%. Because the energy consumption for heating up the goods and the machine is still equally high, the total energy savings are yet, with 20 to 30%, smaller than the savings in water, chemicals, and salt.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention is described in further detail with reference to embodiments of the invention, which are shown in the accompanying drawings.

FIG. 1 shows a sectional view of the centrifugal dyeing apparatus, comprising a spraying tube and a rotatable dyeing beam, during a rotating operation.

FIG. 2 shows another sectional view of the centrifugal dyeing apparatus, comprising a spraying tube and a rotatable dyeing beam, during a rotating operation.

FIG. 3 shows a detail of the support sustainer fixture according to an alternative embodiment.

FIG. 4 shows a detail of the support sustainer according to an alternative embodiment.

FIG. 5 shows a detail of the support sustainer fixture according to an alternative embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1 shows the centrifugal dyeing beam 100 according to an exemplary embodiment of the invention in a sectional view after loading the container 1 with the dyeing beam 2. As known from beam dyeing, the sheet form is wound onto the dyeing beam 2 in the region of the perforation 37 of the tube 3 and is thus forming a lap 4. Due to the fact that sheet forms are produced in different widths, covering sheets 22 are provided, which block the perforated regions which are located on the sides of the lap and which are not covered by the lap, because otherwise large parts of the treating float would pass not through the lap, but through the uncovered perforation 37 of the dyeing beam 2. These covering sheets 22 can be further equipped with radially extending supports 23 so that the lap 4 cannot axially displace itself during treatment. Optimally, these supports 23 are adapted to the layer thickness.
According to an exemplary embodiment of the present invention, the means to radially support the lap 4 primarily comprises the components which are hereafter described. Lying onto the lap 4 over the entire width of the lap 4, the perforated support sheets 5 are positioned on the lap 4. Each one of the support sheets 5 respectively covers a part of the circumference of the lap 4. Ideally, all support sheets 5 together cover the whole circumference of the lap. For the treatment of longitudinal inelastic woven textile, it can yet be sufficient that at least 10% of the circumference of the lap 4 is supported. Because the support sheets 5 are made of thin metal sheets, they can also overlap each other.
The support sheets 5 are attached to the support sustainers 6 by tube clips 32. The support sustainers 6 are adjacently attached to the dyeing beam 2 by the support sustainer fixtures 7 at, preferably, the left and right side of the lap. Various alternative embodiments of this attachment between the support sheet 5, the support sustainer 6, the support sustainer fixture 7, and the dyeing beam 2 are here possible. The adaption to the layer thickness of a lap 4 can be realized between all attachments or their combinations. Further, it is possible that a single part is made out of individual parts of the supporters. So, for instance, a support sustainer 6 and two support sustainer fixtures 7 can be constructed as a single part.
Also, it is possible to construct a single part out of the support sustainer 6 and the support sheet 5.
During operation, the support sustainers 6 support the lap 4 along the entire width of the lap (goods) 4. The support sustainers 6 radially support the lap 4 during operation, wherein the support sustainers 6 are attached to the dyeing beam 2. Hereby, the following features are advantageous and realized in this embodiment:

a) In the reference frame of the dyeing beam 2, which, during operation, rotates around a rotation axis 40, the support sustainers 6 are arranged stationary to the dyeing beam 2. Particularly, the support sustainers 6 are here parallel (coaxially) arranged to the rotation axis 40, as shown especially in FIGS. 1 and 2.
b) The support sustainers 6 are attached on both sides and at the left and right side of the lap, respectively. Therewith, even at high numbers of revolutions, a relatively stiff arrangement of the support sustainers 6 with respect to the rotation axis 40 is achieved.
c) The distance and/or the position of the support sustainers 6 to the rotation axis 40 is certainly fixed during operation, but adjustable during a standstill. Therewith, before the dyeing beam rotates, the support sustainers 6 and, if applicable, thus also the perforated support sheets 5 can be adjusted down to the diameter of the lap.

Hence, with the support sustainers 6, which are all positioned with the same specified and firmly adjusted radial distance to the rotation axis, and the perforated support sheets 5, which are all positioned with the same specified and firmly adjusted radial distance to the rotation axis 40, a symmetric form of the lap, which is mainly invariable during operation, can be sustained. This is further supported through the axial supports 23 because these can be provided so that the lap 4 is not axially moving during operation.
FIG. 2 exemplarily shows how the support sustainer fixtures 7 are radially adjustably arranged at the side plates 38 of the dyeing beam 2. Because it is advantageous for the wrapping of the sheet form if the tube 3 of the dyeing beam 2 is clear of parts sticking out, in the shown solution, the support sustainer fixtures 7 are attached turnably around the close-tolerance screw 34 so that the support sustainer fixtures 7 can be retracted and arrested in the retracted position with the spring bolts 33 for the wrapping or the unwrapping of the sheet form. After the wrapping, the support sustainer fixtures 7 are fixated in the position adapted to the lap with the same spring bolts 33.
The support sustainers 6 can be connected to the support sheets 5 by means of the tube clips 32. The unit, comprising the support sustainer 6, tube clip 32, and the support sheet 5, is located at the support sustainer fixtures 7 with the spring bolts 13.
In a mounted state, the support sheet 5 is thus connected to the support sustainer 6 through the tube clips 32. The support sustainer 6 is connected to the support sustainer fixtures 7 through the spring bolts 13. The support sustainer fixtures 7 are fixated on the side plates 38 of the dyeing beam 2 in the position adapted to the lap 4. Hence, the lap 4 is held between the perforated support sheet 5 and the tube of the dyeing beam 2, which comprises, at least in the region of the lap 3, the perforation 27, and thus can no longer radially disarrange itself.
In the alternative embodiment, which is exemplarily shown is FIG. 5, the function of the support sustainer fixtures 7 is provided by a long screw 35. The unit, comprising the support sustainer 6, the tube clip 32, and the support sheet 5, is torn to the lap 4 by means of the screws 35 and the screw nut 39, which is welded to the side plates 38, and the unit, comprising the support sustainer 6, the tube clip 32, and the support sheet 5, and the dyeing beam 2 are therewith connected. To avoid that the screw 35 loosens itself during operation, the screw 35 is yet secured by a holding screw 36. This arrangement has the advantages that the unit, comprising the support sustainer 6, the tube clip 32, and the support sheet 5, can be adjusted to the layer thickness of the lap 4 in an even more accurate way and that, if necessary, a pretension can be provided by the screws 35.
A further alternative embodiment of the location of the support sustainer 6 is an arrangement in which the support sustainers 6 are located not at the side plates 38 of the dyeing beam 2, as described above, but movably on the tube 3 of the dyeing beam 2.
In the alternative embodiment, as exemplarily shown in FIG. 3, the function of the support sustainer fixture 7 is provided by a long screw 35. The screw 35 connects the unit, comprising the support sustainer 6, the tube clip 32, and the support sheet 5, with the tube 3 of the dyeing beam 2. The screw nut 39 is welded to the internal side of the tube 3. The tube 3 comprises a hole in the region of the nut 39 so that the screw 35 can be inserted through the tube and torn. The screw 35 is then also secured with a holding screw 36.
It is also possible that the support sustainers 6 are radially movably arranged by means of the in most cases supplied supports 23. Similarly to the solution shown in FIG. 3, the screw nut 39 can be arranged not at the tube 3, but at the supports 23. Hence, the unit, comprising the support sustainer 6, the tube clip 32, and the support sheet 5, is connected with the tube 3 of the dyeing beam 2 through the screws 35, the screw nuts 39, the supports 23, and the covering sheets 22.
Because a low self-weight in coexistence with a high bending strength for each of them is advantageous, the support sustainers 6 are preferably formed as closed hollow profiles, like, as exemplarily shown, round tubes or, exemplarily, four-edged hollow profiles.
In the alternative embodiment exemplarily shown in FIG. 4, the hollow profile is formed by the support sustainer 6 and the support sheet 5. This solution can replace the unit that comprises the support sustainer 6, the tube clip 32, and the support sheet 5. The support sustainer 6 must comprise holes so that the treating solution can radially leave the support sustainer 6. Advantageously, both the support sustainer 6 and the support sheets 5 are made of perforated metal sheets. This solution has the advantage that a low self-weight in coexistence with a high bending strength can be provided.
Dependent on the number of revolutions necessary for treating the lap 4 as well as the width of the dyeing beam and of the lap, respectively, in addition to the above mentioned support sheets 5, support sustainers 6, and support sustainer fixtures 7, it can be necessary to apply one or more straps 24 over the support sustainers 6 and the lap 4. Because the straps 24 are tightly fitted to the support sustainers 6, they strengthen also the perforated support sheets 5 so that these do not lift-off from the lap 4 during treatment. The straps 24 have to be adjustable in length so as to lie free from play or with slight pretension on the support sustainers 6 or support sheets 5.
The number of units, comprising the support sustainers 6, the tube clips 32, the support sheets 5, and the support sustainer fixtures 7, depends on the diameter of the lap 4. At least three units are necessary to stabilize the lap 4. The larger the circumference of the lap 4, the more support sustainers 6 and support sheets 5 are necessary to stabilize the lap 4.
The support sheets 5, support sustainers 6, and support sustainer fixtures 7 are located in the container 1, advantageously, even before the dyeing beam 2 being wound is inserted. For centrifugal dyeing apparatuses 100 for which the container 1 is not provided in the form of a pressure vessel, the dyeing beam 2 can be rotatably mounted in the machine. The sheet form is then directly wound onto the dyeing beam 2 which rotates in the container 1. In this case the support sheets 5, the support sustainers 6, and the support sustainer fixtures 7 must be mounted through mounting openings provided in the casing of the container 6.
At the time, where the lap 4 is both sideways and radially secured against a displacement, the process can be initiated. The dyeing beam 2 is brought into rotation through the geared motor 8, two gearwheels 9, 10, and the tappet 11. The dyeing beam 2 can be sustained in rotation during the entire process workflow.
The support sustainers 6 are preferably mounted to the unperforated regions of the tube 3 of the dyeing beam 2 through support sustainer fixtures 7 on the left and right side of the lap 4 and, respectively, to both sides of the lap 4. The support sustainer are advantageously mounted to the side plates 38 of the dyeing beam 2 through the support sustainer fixtures 7 on the left and right side of the lap 4 and, respectively, to both sides of the lap 4.
As it is common for all discontinuous dyeing machines and apparatuses, the centrifugal dyeing apparatus 100 can be filled with hot or cold water through valves 26, 27. Further, the required chemicals, dyes, and salt can be metered out into the water my means of the dyestuff preparation tank 28, the fetch pump 29, and the valve 30. The circulation pump 14 pumps the mixture of water, chemicals, and dye through the heat exchanger 31 and the spraying tube 17 in the rotating dyeing beam 2. The mixture can be heated or cooled with the heat exchanger 31.
The mixture, which is sprayed through the spraying tube 17, is pressed to the inner wall of the dyeing beam 2 by the centrifugal force and forms a float layer 21. For tight sheet forms and low rotational speeds, the height of the float layer 21 is limited by the openings 12 located at the side areas of the dyeing beam 2. The float surplus 20 can leave the dyeing beam 2 through these openings 12. For very penetrable sheet forms and high rotational speeds, it is possible that a float layer 21 is not built up. The mixture arrives at the lap 4 through the perforation 27 and passes it. The mixture then leaves the lap 4 over the perforated support sheets 5 and is collected in the container 1. The mixture again reaches the circulation pump 14 through the suction intake 18 and the suction channel 19 so that the mixture can be kept in circulation. In an optimal way, the rotational speed is increased during a drainage of the mixture so as to improve the draining of the lap 4.
The process workflow is in principle not different from that for jet dyeing machines or also beam dyeing machines. The main difference is that with the described centrifugal dyeing machine 100:

1.) An operational treatment with a bath ratio of less than 3 liter per kilogram sheet form is possible.
2.) It is possible to centrifuge before the rinsing process step so that, for example, sheet forms made of cotton comprising 250% water in relation to the weight of goods contain less than 150% per weight of goods after the centrifuging.

These two process differences are yet adequate to tremendously reduce the consumption of water, chemicals, salt, and energy so that the additional effort pays off both economically and ecologically.

Claims

1. A centrifugal dyeing apparatus comprising

a closable container;

a pump to circulate a treating fluid; and

a driven dyeing beam rotatably supported in said container and arranged to hold a lap made of a textile sheet form and comprising a tube with a perforation;

wherein support sustainers are provide;

wherein said support sustainers radially support said lap; and

wherein said support sustainers are attached to said dyeing beam.

2. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are arranged to be coaxial to said dyeing beam.

3. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are formed as closed hollow profiles.

4. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are adjustable so as to fit to the thickness of said lap.

5. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are arranged alongside the entire width of said lap.

6. A centrifugal dyeing apparatus according to claim 1, wherein perforated support sheets are attached to said support sustainers and wherein said perforated support sheets fit said lap.

7. A centrifugal dyeing apparatus according to claim 6, wherein said perforated support sheets cover at least 10% of the circumference of said lap and the entire width of said lap.

8. A centrifugal dyeing apparatus according to claim 6, wherein each said support sustainers forms a unit together with said perforated support sheets.

9. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are attached to said dyeing beam at an unperforated region of said tube by support sustainer fixtures.

10. A centrifugal dyeing apparatus according to claim 1, wherein said support sustainers are attached to said dyeing beam at an unperforated region of said tube by screws.

11. A centrifugal dyeing apparatus according to claim 1, wherein said dyeing beam comprises side plates attached to said tube.

12. A centrifugal dyeing apparatus according to claim 11, wherein said support sustainers are attached to said side plates of said dyeing beam by support sustainer fixtures that are attached turnably around close-tolerance screws to said side plates, and the position of said support sustainer fixtures can be locked by spring bolts, or wherein said support sustainers are attached to said side plates of said dyeing beam by screws and screw nuts.

13. A centrifugal dyeing apparatus according to wherein at least one strap is applied around said support sustainer and said lap and wherein said at least one strap is adjustable in its length.

14. A centrifugal dyeing apparatus according to claim 1, wherein said container is constructed as a pressure vessel and wherein said dyeing beam is removable from said container and wherein a spraying tube arranged concentrically to the dyeing beam is provided.

15. A centrifugal dyeing apparatus according to claim 1, wherein watery solutions including at least one of a solvent and CO₂in a supercritical state is used as said treating fluid.