WO2021066759A2

WO2021066759A2 - A method of pi ece dyeing and dry ng of text le products in an individual mach i ne with spraying method without usi ng any watering system

Info

Publication number: WO2021066759A2
Application number: PCT/TR2019/050813
Authority: WO
Inventors: Beytullah Ulaş; M.Gözde OK
Original assignee: Ug Teksti̇l Tasarim Arge Üreti̇m İthalat İhracat Pazarlama San. Ti̇c. Ltd. Şti̇.
Priority date: 2019-10-01
Filing date: 2019-10-01
Publication date: 2021-04-08
Also published as: WO2021066759A3

Abstract

The present invention relates to a textile machine and chemical process thereof, that enables textile products to be dyed and dried in a non-aqueous medium by using a spraying method in an individual machine which is to be used in textile and the garment industry.

Description

A METHOD OF PI ECE DYEI NG AND DRYI NG OF TEXTI LE PRODUCTS I N AN

I NDI VI DUAL MACH I NE Wl TH SPRAYI NG METHOD Wl THOUT USI NG ANY

WATERI NG SYSTEM

Field of the I nvention

Background of the I nvention (Prior Art)

Textile washing-dyeing industry is ranked as one of the leading industries for polluting nature. One fifth of the entire industrial pollution of clean water is only caused by dyeing and finishing processes.

SIWI , which is an NGO centered in Stockholm, revealed in a study on water consumption in 2016, that underground waters used in dyeing and printing processes carried out in China corresponds to 10% of the water amount used by the entire industry, which amounts to 2,15 billion tons in total. BGMEA, a trade organization of garments manufacturers in Bangladesh renowned for dyeing industry has announced that they will raise their exports up to $50 million in 2021 and target $82,5 billion in 2030. I n the event that traditional methods are still used in the future, 3,400 billion tons of water will be wasted in order to achieve such targets in 2030. According to the PACT’S report, such an amount corresponds to the water need of 75 million people per year.

Today, more than 3.600 textile dyes have been produced and used by the dyeing industry, which are mostly of toxic nature and hazardous on human health. Moreover, it is assumed that 80% of the entire industrial waste water is not treated before being discharged to the environment.

The methods known from the prior art have the following ratios:

I n textile dyeing processes, in order to dye a product of 100 kg; 4,500 liters of water, 75 kwh energy, a time period of 225 minutes, 3 machines (comprising the steps of dyeing, wringing and drying) and at least 3 personnel are used. Similarly, for an effecting process; for a product of 100 kg, 500 liter water, 20 kwh energy, a period of 90 minutes, 3 personnel and 3 machines (comprising the steps of effecting, rinsing and drying) need to be used. The machines used in the prior art are only used as a washing machine for dyeing. The products dyed are then subjected to various processes including drying and rinsing in separate machines. Furthermore, in aforementioned systems, fluid discharge (waste water discharge) is provided. Therefore, the waste water containing a great amount of chemical substances come directly in contact with the environment without being treated. This results in various environmental damages including pollution in seas and rivers and hazards on land, etc. as well as not short-term but severe long-term damages, which may destroy the balance of the nature in return. I n short, a discharge system contradicts with a closed loop system that is aimed to be achieved in the textile industry.

I n the machine used in the prior art, conventional aqueous processes have been carried out by using a spraying method with the ratio of 1/3 flotte- 1/5 flotte; being used with a circulation system in an attempt to dispense dyeing properly.

As mentioned above, several serious environmental damages may occur particularly when dyeing and finishing processes including (bleaching (pre-finishing), coloring (dyeing, printing), dressing (finishing)) are applied in certain processes that are mostly performed in the textile industry. Nowadays it is deemed crucially important to reduce such damage and provide sustainable solutions. Accordingly, in order to bring the 2020 commitments into action that the World Environment Organizations have requested from global brands, sustainable and environment friendly textile machines and chemical processes are needed, which enable textile products to be concurrently dyed and dried, which have low water consumption, and are easy to use and energy-efficient as well.

Brief Description and Aims of the I nvention

The present invention relates to a textile machine and to a chemical process thereof, that enables textile products to be dyed and dried in a non-aqueous medium by using a spraying method in an individual machine in order to be used in textile and the garment industry, which achieves the aforementioned requirements, eliminates disadvantages, and also brings some additional advantages.

The invention, with the solution used in the inventive textile machine, ensures a reduction of 96,8% consumption, an energy saving of 80% , time saving of 73,3% and a reduction of 90% of chemical use when compared to the systems that are being currently used.

I n the textile machine according to the present invention, textile products are dyed, dried and scrooped collectively (in one machine and one process). Thus, saving on energy and time is ensured.

I n the invention, a closed loop system is provided. Therefore, water discharge is not required in the textile machine and machining process. A very little amount of water is used in the invention and additionally the amount of water or solution that remains/may remain after the products absorb the entire solution evaporates. Thus, since any waste water discharge does not occur, environmental damages will be substantially decreased.

I n the textile machine according to the present invention, two nozzles are provided. These nozzles enable the solution to be sprayed simultaneously onto the products at a determined pressure by use of a pump. The dye that remains after the products completely absorb the solution, the amount of solution that may remain evaporate during the process of drying. Therefore, any discharging process is not needed. With the help of such a special solution, the reactive agent, Asudel and direct dyestuff that have been used in aqueous processes before are now dyed and dried in a non-aqueous medium in the same machine and then the product is discharged from the machine in a ready-to-use state. Thus, a substantial reduction in the rates of water and chemicals used is obtained.

With the machine according to the present invention, the drawback of damaging the environment by producing waste water owing to lack of discharging has been completely eliminated and also the present system is an environment friendly system thanks to its low energy consumption. I n addition, a remarkable decrease in the number of machines and personnel used for performing the processes is obtained.

The invention offers a sustainable, environment friendly solution to the sector. As it is both productive and also consumption values are much lower compared to those of conventional processes; therefore the present invention provides significant contribution to the industry.

Definitions of the Drawings of the I nvention

Figure 1 : shows the components of the machine according to the present invention.

Figure 2: is a perspective view of a pump of the machine according to the present invention.

Figure 3: is a perspective view of a reactor of the machine according to the present invention.

Definitions of the Components/ Parts/ Elements of the I nvention

The components/parts/elements illustrated in the figures that are presented for a better explanation of the textile machine and to the chemical process thereof, that enables textile products to be dyed and dried in a non-aqueous medium by means of a spraying method in an individual machine in order to be used in textile and the garment industry are numbered individually, with the definition of each number being presented below.

1 . Machine

2. Reactor

3. Pump

4. Nozzles

5. Heat coils

6. Computer Panel

Detailed Description of the I nvention

I n the medium that is aqueous and require heat in the methods known from the prior art; for example, for a product of 100 kg, 4,500 liters water minimum, 75 kwh energy, a time period of 225 minutes, 3 machines (comprising the steps of dyeing, wringing and drying.) and minimum 3 personnel are used. The machine subject to the invention has reduced these numbers of the system which has reached such high numbers to 60 minutes, 140 liter water consumption, 15 kwh energy, 1 machine and 1 personnel, thereby saving 96,8% of water, 80% energy, and 73,3% of time and saving 90% on chemicals used.

Table 1 shows the comparison of water, chemical, energy and time factors used in conventional (prior art) methods by percentage and the reduction of said factor in percentages by means of the process of the present invention in proportion to that of conventional methods.

TABLE 1

The solution used in the machine according to the invention is formed by combining fabric dye in the range of 0.1% -10% per mass in relation to the weight of the product to be dyed, with a special polyurethane called X100 in the range of 0.1 % - 10% per mass that binds the dye to fibers even before the product is subjected to heat, allows the dye to be homogeneously dispersed into the products being used instead of water and thereby reduces water use, and a UG silicon that enables a soft touching in the range of 0.1 % - 10% per mass to be obtained, has a size in the range of 500 nm to 10 pm, is water-soluble and micro silicon and soda (sodium carbonate) and water in the range of 0.1% -10% per mass.

The water used in the solution according to the invention is preferably demineralized water. The fabric dye within the content of the solution used in the machine according to the invention is preferably reactive dye, Asudel dye and/or direct dye.

I n an embodiment of the invention; the fabric dye within the content of the solution used in the machine according to the invention is pigment dyestuff, synthetic powder textile dye, organic powder dye, wet dye, textile printing dye. I n an embodiment of the invention; The solution used in the machine of the invention comprises alkali buffering and/or wetting agent in the range of 0.1% -5% per mass. Usage rates of the components forming the solution used in the machine according to the invention may vary by color, quality and weight of the product. The special polyurethane used in the invention, due to its cross linking agent and silicon therein, takes charge of the first step in a better binding of the dye to fibers and helps said dye to homogenously disperse into fibers in the process of the invention wherein a very little amount of water is used as polyurethane is an individual dye linker. I n order to enhance the effect of this special polyurethane and to enable the dye to bind to fibers, soda (sodium carbonate) in the range of 0.1 % -10% per mass in relation to weight of the product is used.

Due to the air flow circulating through the machine, as a result of a reaction of the solution of the invention with oxygen, the dye starts to bind to the fibers before the product is subjected to heat. Reaction is enhanced with heat and this leads to a stronger binding. The solution used in the invention homogenously dispenses between the fabric and fibers in the products and thereby homogenous dye transfer is carried out. It also contributes to reduction in water and chemical consumption.

I n the process of the invention wherein the processes of dyeing, drying and scrooping of the product are performed collectively with the textile machine of the invention, the product is initially loaded into the machine, the solution with the weight of 1.5 times more than the textile product and the water with the weight of 1.4 times more than the same (the products with the determined colors min 001%-max20%) are added into the reactor of the machine and continuously blended in the present invention. The solution is transferred into two nozzles located on a front lid through the pump under pressure. The solution is sprayed onto the products contained in the machine under pressure through said nozzles. Subsequently the vapor, piston and vacuum motor are deactivated. At the same time, a drum of the machine rotates at 20 rpm. Rotation speed of the machine may vary as minimum 10 rpm and maximum 100 rpm. The entire operational system of the machine according to the invention is controlled by a computer panel. Once the computer gives an instruction, heat coils apply heat on the products, and such heat allows the solution to bind to fibers and also the products to be preserved. Once the spray pump is activated, the dye homogenously disperses and adheres to fibers with heat (max 80 degrees). The pump and the reactor are stopped, and following a rotation of 5 minutes, the vapor motor and the vacuum motor are reactivated. Finally, after reaching 85 degrees, a control alarm and a stop alarm is activated. Then, the product is controlled and packaged.

I n the prior art, the dye needs to be subjected to 10 separate processes so as to be fixed to the fabric. These variations can be seen in a comparative table (Table 2) which compares the difference in process steps. As the process of the invention takes up short time, the risks wearing out, puncturing, tearing, rotation, distortion of the fabric are substantially eliminated and said risks are reduced up to 90% when compared to the prior art.

TABLE 2

Claims

CLAI MS

1 . A solution for used for dyeing a product and reducing the amount of water and chemicals used in a textile machine wherein the processes of dyeing and drying of the textile products are collectively performed, characterized by comprising;

• Polyurethane at the range of 0.1% -10% per mass that allows the dye to bind to fibers before the product to be dyed is subjected to heat and for said dye to be dispersed homogenously,

• Fabric dye at the range of 0.1 % - 10% per mass,

• Micro silicon having a size range of 500 nm to 10 pm that allows obtaining a soft touching of 0.1% -10% per mass,

• Soda (sodium carbonate) of 0.1% -10% per mass,

• and water.

2. A solution according to Claim 1 , characterized by said fabric dye being a reactive dye, asudel dye, direct dye, pigment dyestuff, synthetic powder textile dye, organic powder dye, wet dye and/or textile printing dye.

3. A solution according to Claim 1 , characterized by said polyurethane comprising a cross linking agent and silicon.

4. A solution according to Claim 1 , characterized by comprising alkali buffering and/or wetting agent in the range of 0.1% -5% per mass.

5. A solution according to Claim 1 , characterized in that the water contained therein is demineralized water.

6. A textile machine (1 ) in which the processes of dyeing and drying of the textile products are collectively carried out, characterized by comprising;

• At least a computer panel (6) through which the entire operation system of the machine is controlled,

• At least a heat coil (5) that allows applying heat on the products and thus allowing the solution to bind to the fibers, wherein the solution ensures a homogenous dye carriage between the fabric and the fibers, and also the products to be preserved.

• An operating method of the textile machine in which the processes of dyeing and drying of the textile products are collectively carried out, characterized by comprising the process steps of;

• Adding the textile product, the solution according to Claim 1 that weighs 1.5 times more than the textile product, and the water into the reactor (2) of the machine,

• Transferring said solution into at least one nozzle (4) through the pump (3),

Spraying said solution onto the products inside the machine (1 ) through at least one nozzle (4).