WO2014017994A1

WO2014017994A1 - A machine for surface treatment application method in sportswear products

Info

Publication number: WO2014017994A1
Application number: PCT/TR2013/000241
Authority: WO
Inventors: Ayhan İYİGÜN
Original assignee: Erak Giyim San.Ve Tic. A.S.
Priority date: 2012-07-23
Filing date: 2013-07-08
Publication date: 2014-01-30

Abstract

The present invention relates to an application machine (500) in which the application method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals; and comprising: a body (100); a drum (110) mounted in said body (100), wherein chemical substance is sprayed to the products provided therein; a dosing unit (200) enabling regular and precise chemical substance feeding; sets (120) provided inside said drum (110) with symmetrical positions, having same characteristics and enabling movement of the products in bulk homogeneously inside the machine (500) from back to front and from front to back; a motor (130) provided outside of said body (100); driving elements (140) connected to said motor (130); and a cover (150) provided in the front part of said body (100) and having an opening in the center thereof is developed.

Description

A MACHINE FOR SURFACE TREATMENT APPLICATION METHOD IN SPORTSWEAR

PRODUCTS

Field of the Invention The present invention relates to an application machine in which the method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals.

In particular, the present invention relates to an application machine comprising a body having a drum, special sets, a motor, driving elements and a cover; a dosing unit having a dosing pump, an actuated valve and a spray nozzle; and venturi tubes; and in which a method comprising application preparation, chemical substance application, application termination, product removal, post processes and quality control is carried out.

Background of the Invention

Nowadays, some applications are carried out on the sportswear products manufactured in the textile industry before and after the manufacturing in order to attract the attention of the user, to meet user needs and to eliminate problems that may arise during the use of the product. Said applications are implemented by the application of chemical substances on the sportswear product through spraying or dipping and through felt and brushrarely; however, said applications are not preferred due to imperfection of manufacturing.

Among the applications, described above in general, performed on sportswear products, two applications that are widely used in the current art stand out. The first of these applications is the manual spray application. In this application, the chemical substance to be applied is individually applied on the respective sportswear product by spray guns. A disadvantage of said application is that since two to three times spraying is carried out on the sportswear product, irreversible gaps are formed on the respective product. In addition, gaps and imbalances occur in the crotch, around the leg and belt of the respective product. This situation gives rise to deterioration of the cut, creation and pattern of the manufactured product. Another disadvantage of the aforementioned application is that since the sportswear product is opened by being inflated in the boots, the applied chemical substance penetrates into the product. This situation, in turn, can lead to significant strength loss in the respective product. In addition, excessive inflation of the respective product being inflated in the boots for performing the application leads to differences in shrinkage values of said product. This means that during use of the product the user would experience problems.

A further disadvantage of said application is that a difficult process is required for implementing said application. Implementation of the application directly by the workers may give rise to putting stress on the worker as well as health problems being experienced by said worker due to situations such as being exposed to the chemical substance inhalation, etc. In addition, labor costs are very high due to use of direct labor and chemical substance costs are very high due to uncontrolled spraying in open areas.

The second application used widely in the current state of the art is the application of the chemical substance on the sportswear product by means of impregnation through dipping and soaking or shrinking in the kier. In this application, initial soaking and subsequent impregnation of the respective product in the kier having perforated drum, filled with the chemical substance is provided. Here, the amount of chemicals in water used for performing complete application is high.

A disadvantage of said application is that high amount of chemicals such as resin, etc. are used for the application. Taking into account the fact that the used chemicals will not be employed again, high wastage of chemicals and chemical costs associated therewith arise.

Another disadvantage of said application is that significant losses in strength emerge due to the high amount of chemicals introduced and soaking of the respective product inside chemicals with said characteristics. Such losses in strength shorten the life of the product and thus lead to user dissatisfaction. Another disadvantage of said application is that cracks occur on the sportswear product soaked in chemicals by means of said application during post processes such as drying and transport performed after application. The cracks formed on the respective product lead to significant quality problems. In addition, utilization fastness of the respective product is also low due to said cracks. This situation, in turn, can lead to minimization of the customer satisfaction.

Another disadvantage of said application is that cost of chemicals is very high due to the high amount of chemicals requirement of the process of said application. This, in turn, unpredictably increases manufacturing costs of the sportswear product on which the application is performed. In addition, both energy and labor costs increase due to expression, transport, drying processes performed in accordance with said application.

There are also overall disadvantages of the applications, disadvantages of which are separately described above for each process. The most important of these disadvantages is that the outcomes obtained as a result of performing said applications do not have a certain standard. In addition, obtained standards are much lower than required. The quality of the respective product is also lower due to the lower standards. The sportswear products obtained as a result of the applications performed in this manner are offered to the market with a low utilization fastness and a poor quality. This, in turn, reduces the market share of respective clothing products by making the marketing thereof difficult. In addition, long time use of the sportswear products having low utilization fastness and quality in accordance with the utilization purposes is not possible. The second common disadvantage of both aforementioned applications is that manufacturing process is very difficult, irregular and performance thereof is very low as said applications are carried out by conventional methods. Second quality product ratio is also quite high due to the processes carried out in this way and problems emerging in the products on which application is performed. This, in turn, means wastage and has a cost increasing effect in the manufacturing. In addition, costs such as energy, labor, etc. are also high because of the conventional methods.

Consequently, the need for an application machine eliminating the aforementioned drawbacks, in which the application method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals and insufficiency of existing solutions in the current state of the art made the development in the respective technical field necessary.

Objects of the Invention

The present invention is developed by considering the existing situations and seeks to solve the above mentioned drawbacks.

The object of present invention is to provide an application machine in which the method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals.

Another object of the present invention is to provide chemical substance and labor savings of up to 90% and 20-25% energy savings by the application of the chemicals in bulk on the sportswear products instead of individual applications thereof. Another object of the present invention is to enable Obtaining products with high standards, utilization fastness and quality thanks to the application performed by the employed method and machine. Thus, it is to also minimize problems such as cracks, loss of strength, wear, gap formation, etc. occurring on the respective product.

Another object of the present invention is to reduce the second quality product ratio below 1% which is around 4-5% by means of the high utilization fastness and quality obtained as a result of the application. Thus, it is to minimize the amount of wastage in the manufacturing of the product and to eliminate the unnecessary cost increases occurring at this point.

Another object of the present invention is to provide savings between 20-30% in repairs made in the products and in costs of labor, machinery use and energy associated with said repairs due to the reduction in second quality product ratio.

Another object of the present invention is to provide uniform distribution of the sportswear products introduced into application by regular movement thereof in the machine thanks to the sets provided in the application machine drum having special design and setting. Thus, it is to introduce equal amount of chemicals on the respective product in spraying performed inside the machine.

Another object of the present invention is to create a mechanical effect enabling contact of the products with each other by continuous rotation of the respective products inside the machine drum thanks to the special sets and to perform homogeneous and continuous transfer of chemicals to the respective product.

Another object of the present invention is to enable the chemical substances sprayed in the front part of the machine remain unstable thanks to the specially designed circulation system provided on the machine and the two mutual venturi tubes provided in the rear part of the machine. In other words, it is to continuously circulate the chemical substance.

Another object of the present invention is to enable easy cleaning of the machine fans without any contact with water, with just by washing of the air flow path thanks to the venturi tubes provided on the edges of the drum. Thus, it is also to minimize the failures that can occur in the machine fans.

Another object of the present invention is to provide further treatment with the chemical substance of the product on which application is performed and to also enable bonding of the chemical substance to the respective product by 80-90% thanks to the continuous circulation provided in the application machine. Thus, it is to achieve maximum efficiency in application by keeping the chemical substances used in the application at a minimum level.

Another object of the present invention is to make the circulation and distribution of the chemical substance homogeneous thanks to the application chemical being fed from the front part of the machine and being vacuumed from the rear part of the machine. Thus, it is to keep application chemical substance absorption of the respective products high and uniform. Another object of the present invention is to provide application having high efficiency and performance thanks to the application of the chemical substance provided with uniform and homogeneous circulation in the machine at high rates to the respective product. Thus, it is to provide fast and continuous manufacturing thanks to said high efficiency and performance. Another object of the present invention is to also increase the efficiency and performance of the post processes performed after the application thanks to the high efficiency and performance of the employed application. Thus, it is to save costs such as labor, energy, etc. allocated to the said post processes. Another object of the present invention is to provide the sportswear products being subjected to the application with high quality and utilization fastness thanks to the application of the chemical substance provided with uniform and homogeneous circulation to the respective product at high rates.

Another object of the present invention is to make the application process quite simple, predictable and controllable thanks to the method applied and machine used. Thus, it is to make all information regarding the manufacturing carried out to be understandable and accessible.

Another object of the present invention is to increase retailer as well as consumer satisfaction to maximum levels thanks to the advantages mentioned above.

In order to achieve the aforementioned objects, an application machine in which the application method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals; and comprising: a body; a drum mounted in said body, wherein chemical substance is sprayed to the products provided therein; a dosing unit enabling regular and precise chemical substance feeding; sets provided inside said drum with symmetrical positions, having same characteristics and enabling movement of the products in bulk homogeneously inside the machine from back to front and from front to back; a motor provided outside of said body; driving elements connected to said motor; and a cover provided in the front part of said body and having an opening in the center thereof is developed.

The structural and the characteristic features and all advantages of the present invention will be understood more clearly with the following figures and the detailed description written by referring to said figures and therefore, the evaluation needs to be done by taking said figures and the detailed description into consideration. Description of the Figures

Embodiment of the present invention and advantages thereof with the additional components must be considered together with the figures explained below in order to be fully understood.

Figure 1 is the perspective view of the application machine in which the application method according to the present invention is carried out.

Figure 2 is the two dimensional side view of the application machine in which the application method according to the present invention is carried out.

Figure 3 is the two dimensional top view of the application machine in which the application method according to the present invention is carried out. Reference Numbers Used in the Figures

100- Body 210- Dosing Pump 110- Drum 220- Actuated Valve

120- Special Set 230- Spray Nozzle 130- Motor 300- Venturi Tube 140- Driving Element 310- Fan 150- Cover 400- Timer Relay 200- Dosing Unit 500- Application Machine

Detailed Description of the Invention

In this detailed description, the application machine (500) in which the application method according to the present invention is carried out, described only for a better understanding of the subject without constituting any restrictive effect. Accordingly, the present invention relates to an application machine in which the application method is carried out, wherein the application machine (500) in which, particularly, the steps of the method consisting of application preparation, chemical substance application, application termination, product removal and quality control is performed comprises the following: a body (100) having a drum (110), special sets (120), a motor (130), driving elements (140) and a cover (150); a dosing unit (200) having a dosing pump (210), an actuated valve (220), a spray nozzle (230); and venturi tubes (300).

Here, firstly, the application machine (500) in which the application method according to the present invention is carried out will be described. Then, application stages including the described application machine (500) will be described.

Accordingly, in Figures 1 , 2, and 3 perspective, two dimensional side and top views of the application machine (500) are given, respectively. According to the figures, the body (100) is the element keeping the application machine (500) together, enabling mounting of the other elements and allowing for realization of the application. Said element comprises the drum (110), special sets (120), motor (130), driving elements (140) and the cover (150). The drum (110) is in the form of a metal cylinder having holes for filling said body (110). The parameters of the drum (110) such as the depth, diameter, diameter and number of holes is exclusively set for enabling homogeneous distribution of the product to be subjected to application and the chemical substance to be used in the application. The cover (150) is provided at the mouth (150) part of the drum (110). The cover (150) has a structure with an opening in the central part thereof. There are two functions of the cover (150). The first one, thanks to the opening and closing feature thereof, is to enable placement of the wear products to be subjected to the chemical substance application into the drum (110) and closing of the mouth of the application machine (500) upon placement operation. The second one, thanks to the opening in the center thereof, is to provide spraying of the chemical substance into the drum (110) through the spray nozzle (230) and thus to the respective wear product provided inside the drum (110). In this way, the respective wear product placed into the drum (110), mouth of which is closed with the cover (150), rotates by means of the drum's (110) rotation around its own axis. Thus, the chemical substance accumulation on the respective sportswear product to be subjected to the application is effectively distributed by the mechanical effect provided thanks to said movement of the drum (110). Again, homogeneous contact of chemical substance and the respective product is further provided by ventilation of the respective sportswear product thanks to said movement of the drum (110). 4 special sets (120) mounted on the inner surface of said drum (110) in symmetrical positions and having identical structures are provided. Both the positions and structures of these sets (120) are specially designed. The function of the special sets (120) is to move the respective sportswear products placed in bulk into the drum (110) from front to back and from back to front during the rotation of the drum (110) by exhibiting a uniform and homogeneous distribution inside the drum (110). In this way, the respective sportswear products can homogeneously and proportionally receive the chemical substance in the desired manner during the spraying performed. Special sets (120) can provide said movements to the respective sportswear product by means of special design and position thereof. Driving of the drum (110) and the other moving elements provided inside the body (100) is provided by the motor (130) provided outside the body (100). The energy obtained in the motor (130) is transmitted to the driving elements (140). Driving elements (140) rotate with the energy they receive. Said rotational movement is transmitted to the drum (110) by means of the driving element (140) connected to the drum (110) through the center thereof. One of the most important parts of the application machine (500) in which the application method according to the present invention is carried out is the dosing unit (200). This unit (200) serves as the receptacle filled with the chemical substance to be used in the application and amount and level of which is determined previously according to the characteristics of the application. In addition, in chemical substance application, said unit (200) again, uniformly and seamlessly feeds the chemical substance according to the characteristics of the application being performed onto the respective sportswear products provided inside the drum (110) and provides application thereof by means of spraying. Thus, chemical substance application can be done consistently and on a uniform basis. This, in turn, means eliminating the errors that can occur on the surface as it does not utilize human power in said processes. Following is provided in the structure of said dosing unit (200): a dosing pump (210), an actuated valve (220) and a spray nozzle (230). Dosing pump (210) is operatively connected to the dosing unit (200). The function thereof, thanks to the energy and driving force created thereby, is to provide feeding of the chemical substance into the drum (100) by means of the spray nozzle (230) in accordance with a predetermined level for the chemical substance application. In other words, necessary amount of the chemical substance for the application is fed. In addition, it also provides recycling of the remaining portion of the applied chemical substances without being wasted to the dosing unit (200) again. Actuated valve (220) is provided between the dosing unit (200) and the spray nozzle (230). The function thereof is to cut chemical substance transfer into the drum by automatically stopping the operation of the dosing unit (200) in case of a possible power loss during the execution of the application. Thus, wastage of chemical substance in the power loss is prevented. Spray nozzle (230) is operatively connected to the actuated valve (220) at the end of the dosing unit (200). Said nozzle (230) is positioned such that the end portion thereof enters into the drum (110) through the opening in the center of the cover (150) provided in the front part of the drum (110). The function of said nozzle (230) is to homogeneously apply the conditioned chemical substance transferred thereto from the dosing unit (200) by means of spraying method onto the sportswear product provided inside the drum (110). The important point herein is to set the dosing duration and performing the spraying process with a wide angle. During said spraying and application, spraying duration and also the distribution of the chemical substance can be set in accordance with the desired application characteristics by means said nozzle (230).

Referring to Figure 3, two identical venturi tubes (300) are provided in the rear left part of the body (100) and the drum (110) of the application machine. The functions of said tubes (300) is to provide uniform distribution of the chemical substance onto the respective sportswear product by providing said chemical substance applied to the respective sportswear product provided inside the drum (110) with an unstable state by the vacuum created thanks to the fans (310) comprised in the structure thereof. Bonding of the applied chemical substance onto the respective sportswear product with a high ratio of 80-90% is provided thanks to the air circulation generated during realization of said processes. In addition, the out flow of the chemical substance used in the application is reduced by 30% during the execution thanks to the venturi tubes (300). Thus, maximum utilization of the chemical substance during the application process is provided and wastage thereof is prevented. The timer relay (400) provides operation of principally the venturi tube (300) and fans (310) in the respective machine for the desired duration after the termination of the application process. Thus, chemical substance-product interaction is carried out for the specified duration thanks to the air circulation provided after the application. This, in turn, has a positive effect on efficiency and quality of the application.

In the application machine (500) described above with the elements, positions and functions of said elements, the application method according to the present invention applied to the sportswear products is carried out in the following stages. A- Application Preparation:

In this stage, application machine (500) is made ready for the application to be made. For this, firstly, the sportswear products to be provided with application are placed into the drum (110) by opening the cover (150) in the front part of the drum (110) and then said cover (150) is closed. Then, the chemical substance is filled into the dosing unit (200) so as to have the characteristics such as amount, viscosity, etc. in accordance with the application characteristics. Then, settings of all the application effective elements provided on the application machine (500) are optimized so as to be in accordance with the application purposes and made ready for the application. Finally, motor, dosing pump and venturi tubes of the application machine are operated. An important point to note here is that the rev of the application machine (500) is set so as to be the most appropriate for the distribution of the respective sportswear product and for the homogeneous chemical substance application. Respective machine is fully prepared for the application upon setting up all of the mentioned elements.

B- Chemical Substance Application In this stage, the drum (110) starts to operate in the application machine (500) with settings of all elements have been made in accordance with the application, respective sportswear product have been placed into the drum (110) and chemical substance have been made ready for dosing. With the movement of the drum (110), the chemical substance provided in the dosing unit (200) filled previously by the dosing pump (210) passes through the actuated valve (220) and reaches the spray nozzle (230). The chemical substance delivered to the spray nozzle (230) is conditioned therein and sprayed with a wide angle onto the respective sportswear product provided inside the drum (110) by means of the spray method. Said spraying process is initiated within a few seconds and chemical substance application starts upon rotation of the drum (110). The respective sportswear products provided inside the drum (110) and being sprayed with the chemical substance as such are regularly moved from back to front and from front to back while being rotated in the drum (110) by means of 4 special sets (120) provided therein. Thus, a more homogeneous bonding of the respective sportswear products with the applied chemical substance can be achieved. During the application carried out as such, the chemical substance delivered into the drum (110) is made into an unstable state by means of the air circulation created by the vacuum generated by the venturi tubes (300) provided on both sides of the drum. Chemical substance in such an unstable state can be distributed more homogeneously and evenly on the respective sportswear product. All parameters, settings, and controls of the chemical substance application are previously determined and chemical substance application stage is carried out in accordance with the specified parameters such as process duration and dosing duration, speed, etc.

C- Application Termination:

In this stage, application is terminated by stopping the operation of the elements of the application machine (500) upon completion of the chemical substance application in the envisaged duration. The characteristic of this stage is that even though all the moving elements on the application machine (500) are stopped, the fans (310) of the venturi tubes (300) of the application machine continue to operate for the duration specified by means of the timer relay (400). Thus, the application medium provided inside the drum (110) by the air circulation, proceeds forward for the time period specified by the timer relay (400) even though the machine is stopped. This, in turn, means continuation of the chemical substance-product interaction for the specified duration and has a positive effect on efficiency, performance, and quality of said interaction.

D- Product Removal, Post Processes and Quality Control

In this stage, the respective sportswear products provided inside the drum (110) and provided with application are taken out by opening the cover (150) upon completion of the application process in the application machine (500). Here, the initial quality control is visually performed on the respective sportswear products taken out. The sportswear products passing the initial quality control are then delivered, for performing post processes, firstly to the fixing, then to post washing and lastly to the final drying. The purpose of fixing is the complete bonding of the applied chemical substance onto the respective sportswear product. The sportswear products leaving the fixing are introduced to the post washing and chemical substances that are not bonded thereon are removed. Lastly, application process of the respective sportswear product is terminated with the final drying. After the final drying, final quality control is performed on the respective sportswear products by means of visual as well as mechanical and optionally, chemical methods. The success of the application as well as the degree of process efficiency can be observed thanks to said performed quality controls. Also, corrective or improvement measures for the parameters to be used in the next application can be taken on the basis of the obtained data. This, in turn, means continuous improvement for the application process.

The application machine (500) in which the application method, successfully providing solutions to the aforementioned technical problems, is carried out will be widely used in the respective fields for performing the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. with minimum time, maximum efficiency and performance, fastness of high quality and standards and low costs of energy, labor and chemicals.

Claims

1. An application machine (500) in which the application method for the process of providing the sportswear products manufactured in the textile industry with the utilization characteristics and fastness such as chemical bleaching, surface brightness and lubricity, difference in texture and appearance, strength, etc. is carried out, wherein it comprises the following:

- a body (100);

- a drum (110) mounted in said body (100), chemical substance is sprayed to the products provided therein;

- a dosing unit (200) enabling regular and precise chemical substance feeding;

- sets (120) provided inside said drum (110) with symmetrical positions, having same characteristics and enabling movement of the products in bulk homogeneously inside the machine (500) from back to front and from front to back;

- a motor (130) provided outside of said body (100); driving elements (140) connected to said motor (130); and

- a cover (150) provided in the front part of said body (100) and having an opening in the center thereof.

2. Application machine (500) according to claim 1 , wherein said dosing unit (200) comprises the following:

- a dosing pump (210) operatively connected to said dosing unit (200);

- an actuated valve (220) operatively connected to said dosing unit (200); and

- a spray nozzle (230) operatively connected to the dosing unit (200) and mounted at the end of the actuated valve (220).

3. Application machine (500) according to claim 1 , wherein it comprises the following:

- two identical venturi tubes (300) having fans (310) provided on both sides of said drum (110); and

- one timer relay (400) connected to said body (100).