WO2021133287A1 - Electrical ironing mechanism that applies thermal treatment to the semi-finished fibre reinforced base fabric and thermal treated fibre reinforced base fabric production method - Google Patents
Electrical ironing mechanism that applies thermal treatment to the semi-finished fibre reinforced base fabric and thermal treated fibre reinforced base fabric production method Download PDFInfo
- Publication number
- WO2021133287A1 WO2021133287A1 PCT/TR2020/050165 TR2020050165W WO2021133287A1 WO 2021133287 A1 WO2021133287 A1 WO 2021133287A1 TR 2020050165 W TR2020050165 W TR 2020050165W WO 2021133287 A1 WO2021133287 A1 WO 2021133287A1
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- WO
- WIPO (PCT)
- Prior art keywords
- base fabric
- semi
- fibre reinforced
- finished
- heat treatment
- Prior art date
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Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics
- D06C15/08—Rollers therefor
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C13/00—Shearing, clipping or cropping surfaces of textile fabrics; Pile cutting; Trimming seamed edges
- D06C13/04—Shearing lace or embroidery, e.g. cutting loose threads
Definitions
- the fabric in order solve the humidity problem encountered at the end of the production process of the fibre reinforced base fabric, the fabric is subjected to thermal treatment and following this the packaging process prior to shipment is started.
- the base fabric may be deteriorated due to heat and the homogenous structure of the base fabric can be disrupted.
- the thermal treatment leads to expansion of the base fabric and due to this expansion, the thickness of the base fabric increases and the fabric is deteriorated, the heat subjected to the base fabric cannot be completely controlled and excess usage of thermal energy may be encountered.
- the locking ratio of the materials such as artificial turf that are woven onto this base fabric during the application of this fibre reinforced base fabric to the ground is low, and this reduces the resilience of the materials such as artificial turf located on the base fabric and it is, therefore, possible for materials such as artificial turf to fall out of the base fabric.
- the base fabric is loaded between two cylinders that are heated and the unsmooth parts on the surface are ironed out and homogeneity is tried to be obtained on the fibre material located on the base fabric, and therefore, the technical problems caused by humidity are tried to be overcome.
- the processes of subjecting the fibre reinforced semi-finished fabric can be carried out in different methods.
- One of these methods is using lubricant heating and liquid heaters.
- lubricant heating and liquid heaters In such systems, if an operator that is not experienced performs a wrong operation on the pressure control circuit that controls the pressure of the system, this may lead to a fire. Due to this reason, when the base fabric is subjected to heat treatment using lubricant heating and liquid heaters in order to avoid the problems mentioned above, the fabric needs to be controlled continuously during the entire production period.
- the cylinder that applies the heating process through which the fibre reinforced semi-finished base fabric passes contains materials such as oil or liquid.
- this system must contain a liquid or oil discharge and reserve tank.
- the oil that is heated in the reserve tanks passes through the cylinders and enables the cylinders to heat up.
- pressure is created and this pressure damages the system if any kind of security flaw is present.
- water is poured over the burning oil, the fire cannot be put out and expensive fire extinguishing agents such as foam needs to be sprayed over the fire.
- the usage lives of the lubricant systems that are used during heat treatment are lower in comparison to the electrical heating system subject to our invention.
- the oil that is used needs to be frequently changed in order to ensure that the system operates efficiently and this leads to an increase in production costs.
- it is difficult to intervene as the weight of the cylinder that is filled with oil is very heavy.
- One of the heat treatment application methods in the production of fibre -reinforced base fabrics is the method of heating the cylinder that applies heat treatment with natural gas. Natural gas heats up the water or any other kind of material inside the cylinder the material in the form of water or gas that is heated is passed through the heating cylinder and heating of the cylinder is established. The semi-finished fibre reinforced base fabric that is received through the heated cylinder is subjected to heat treatment and the fabric is tried to be smoothed out and ironed.
- the natural gas heating systems must also have a liquid, gas or oil reserve tank and this leads to the above-mentioned problems.
- heat treatment is applied by means of the heated cylinders that are heated by the transmission of electricity to the resistances that are located inside the tubes available inside the cylinder.
- the fibre reinforcement material located on the base fabric that is unevenly distributed and ragged is smoothed out by means of heat treatment by being subjected to ironing.
- the heat track needs to be completely moved back and following intervention the heat track needs to be brought back to its initial state and this takes up a lot of time.
- the thermal process application section is integrated with the line, in case of a breakdown all of the lines need to be stopped. Production completely stops until the breakdown is repaired. Due to this reason in our invention, the heat treatment application process and the finishing process have been arranged such that it is not integrated with the line. By this means, in order to overcome a problem that is encountered at the heat treatment application section, the line does not need to be stopped before an ironing process and production prior to heat treatment is continued.
- the operator needs to carry out the adjustment process of adjusting the excess on the surface to the desired height without damaging the fibre or the base fabric by means of the surface adjuster available just before the ironing cylinder in order to overcome the uneven distribution or homogeneity problem of the fibre that may be faced during production. These problems cause reduction of the quality of the fibre reinforced base fabric that is produced.
- a ventilation system that is used to discharge the hazardous gasses created during the application of heat treatment in the prior art is not available. This causes the operator to face life-threatening danger during heat treatment and the operator needs to be frequently distanced from this environment.
- a ventilation system has been installed on the top section where heat treatment is applied on the fibre reinforced semi-finished base fabric and it is prevented for the operator to be subjected to chemicals that are discharged together with heat.
- the fibre thickness on the semi-finished base fabric during production cannot be provided as the desired thickness every time. As fibre peaks may occur on the surface depending on this, this leads to production and quality losses.
- a trimmer is used before the heat treatment in order to ensure that the different fibre thicknesses on the base fabric are equalized. For example, while the fibre thickness on the base fabric of the roll prior to the application of heat treatment needs to be 4 mm, in some sections they can be 7mm due to production errors.
- the heat that is to be applied during the ironing of the base fabric that is to be subjected to heat treatment having fibre reinforcement at different thicknesses is fixed and as the heat to be applied to the 4mm fibre and the 7mm fibre is the same, homogeneity following ironing cannot be completely provided.
- a trimming mechanism has been developed that is used prior to ironing in our invention, in order to ensure that the fibre having different thickness on the base fabric is brought to the same thickness.
- the excess sections of the fibre thickness are trimmed by means of this trimming mechanism and the fibre thicknesses are equalized, as a result, equal heat treatment is applied to equal fibre reinforced thicknesses and homogeneity is provided following ironing, and higher quality reinforcement base fabric is produced.
- the electrical heat treatment application mechanism of our invention is a mechanism that performs heat treatment in a separate area that is not integrated with the finishing system that is used after the fibre reinforcement containing muslin is covered and the finishing process is completed. As a result, the technical problems arising from the mechanism that performs heat treatment following the finishing system are overcome.
- a mechanism has been placed on the roll that is available for heat treatment in order to solve the edge winding problems that are encountered on the roll, over which the fibre reinforced base fabric is wound and said mechanism can be moved in four directions being up-down, left and right.
- the control mechanism that can move in four directions has two opposite sensors and it transmits a signal to the control panel in order for the faulty part to be corrected.
- the problem of edge winding of the sections that are faulty in our invention is solved by moving the product to be subjected to heat treatment in the correct direction.
- a trimming apparatus has been installed at the section before the heat treatment section in order to ensure that equal amount of heat is obtained from the cylinder, by bringing the thickness of the fibres located on the base fabric that has different thickness due to production faults, to equal thickness before the fabric is subjected to heat treatment.
- This trimmer is used in order to ensure that the different fibre thicknesses on the base fabric are equalized.
- Figure- 1 Side plan view of the ironing system subject to our invention
- Figure-2 Upper plan view of the ironing system subject to our invention
- FIG-5 Front view of the ironing system subject to our invention
- Figure-6 Rear view of the ironing system subject to our invention
- Figure-7 The view of the 1st condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention
- Figure-8 The view of the 2nd condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention
- Figure-9 The view of the 3rd condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention
- Figure- 10 Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition- 1)
- FIG-11 Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition-2)
- FIG. 12 Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition-3)
- FIG. 13 Detailed view of the winding correction system of our ironing system subject to the invention
- Figure- 14 Detailed view of the fibre trimming cylinder correction system of the ironing system subject to the invention
- Figure- 15 Detailed view of the electrical heating cylinder correction system of the ironing system subject to the invention Brief definitions of the part numbers illustrated in the Figures:
- Air pressure pneumatic piston (for electrical heating cylinder height adjustment)
- An electrical ironing mechanism that applies heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that is used in the production of a carpet by sewing said fibre yams thereon, are fitted properly on the base and a heat-treated fibre reinforced base fabric production method that performs production with this mechanism.
- the ironing mechanism subject to our invention where heat treatment is applied is installed in a different area than the sections where a muslin made of polypropylene and/or fibre material is spread over the base, pinning is performed and following this, the product is wound around a roll.
- Our mechanism is not installed right after the pinning section as opposed to the prior art.
- the electrical ironing mechanism that applies heat treatment in our invention comprises, a fibre reinforced semi-finished base fabric roll expanding apparatus (1), a transfer section (2) that transfers the fibre reinforced semi-finished fabric to the trimming apparatus, fibre trimming apparatus (3) of the fibre reinforced semi-finished fabric, electrical heating apparatus (4) of the fibre reinforced semi-finished fabric, final product winding apparatus (5) and a ventilation section located on the opt section of the electrical heating apparatus.
- the fibre reinforced semi-finished base fabric roll expanding apparatus (1) comprises a winding corrector piston (1.1); a winding corrector sensor (1.2) and a semi-finished fibre reinforced base fabric roll (1.3).
- the faulty wound rolls (1.3) are sensed with the winding correcting sensor (1.2) and are corrected with the winding corrector piston (1.1).
- the roll (1.3) over which the semi-finished fibre reinforced base fabric is wound around, and the fabric is opened by means of the base fabric roll expanding apparatus (1) for preparation before heating.
- the fibre trimming apparatus transfer section (2) of the semi-finished fibre reinforced fabric of the mechanism subject to our invention comprises tension cylinder height adjustment lever (2.1), and a pre-trimming tension cylinder (2.2). By means of this section, the semi finished fibre reinforced fabric is prepared before the trimming process.
- the fibre trimming apparatus (3) used for trimming the fibres of the semi-finished fibre reinforced fabric comprises a fibre trimming cylinder (3.1) a fibre trimming cylinder height adjustment lever (3.2), and a fibre trimming apparatus tension cylinder (3.3).
- the semi-finished fibre reinforced base fabric is brought to equal thickness prior to heat treatment by means of this invention and it is enabled for the fibres to receive an equal amount of heat from the heating cylinders.
- the semi-finished fibre reinforced fabric electrical heating apparatus (4) comprises an electrical heating cylinder (4.2) that consists of a chrome alloy heat cylinder (4.2.1), a heat system resistance rod (4.2.2), resistance rod support table (4.2.3), electrical heat cylinder shaft connection (4.2.4), and an electrical heat cylinder shaft (4.2.5).
- the heating cylinder (4.2.1) is preferably made of chrome alloy; however, it can be made of other materials.
- an air pressure pneumatic piston (4.3) that adjusts the height of the electrical heating cylinder, an electrical heating system tension cylinder (4.4), and a controller (4.5) that controls the entire electrical heating system has been provided.
- a ventilation system (4.1) that enables to discharge harmful gasses that are created, from the environment is provided at the top section of the electrical heating apparatus.
- the mechanism subject to the invention also comprises a final product winding unit cylinder (5.1), a final product roll balancing weight (5.2) and a final product winding roll comprising a final product roll (5.3).
- a final product winding unit cylinder 5.1
- a final product roll balancing weight 5.2
- a final product winding roll comprising a final product roll (5.3).
- a heating system resistance rod (4.2.2) where the electrical resistances that extend along the cylinder inside a tube is located is provided in the heating cylinder (4.2) of our heat treatment application mechanism of our invention. These resistance rods (4.2.2) heat up the heating cylinder (4.2) that shall subject the product to heat treatment.
- the heating system resistance rods (4.2.2) of our invention are mounted to the resistance rod support table (4.2.3).
- the controller (4.5) used in our invention houses a temperature control circuit. This temperature control circuit enables heat treatment control.
- the heat treatment application mechanism subject to our invention enables the smoothing process by applying pressure onto the fibre reinforced base fabric by means of a heating cylinder (4.2) that is heated via the electrical resistance rods (4.2.2).
- the amount of pressure to be applied onto the product and the angles of pressure is adjusted by means of the up and down motion of the cylinder (4.2).
- the quality of the final product is prevented from changing from one fabric to another by adjusting the pressure of the cylinder (4.2).
- the application of pressure at different angles by the cylinder (4.2) that is moved up and down is carried out by acting manually on the bottom section and by using the electronic controller.
- a pressure control circuit is available inside the controller (4.5) and the pressure amount to be applied onto the product is adjusted by said controller.
- a mechanism has been placed on the roll that is available for heat treatment in order to solve the edge winding problems that are encountered on the roll, over which the fibre reinforced base fabric is wound, wherein said mechanism can be moved in four directions being up-down, left and right.
- the control mechanism that enables control is made by two opposite sensors (1.2). These sensors (1.2) transmit a signal to the controller (4.5) in order to correct the faulty section.
- the problem of edge winding of the sections that are faulty in our invention is solved by moving the product to be subjected to heat treatment in the correct direction.
- a ventilation system (4.1) is installed on the top section of the heat treatment section, in order to discharge the harmful gasses created during heat treatment application.
- the harmful gasses that emanate out during the application of the heat treatment is discharged by means of this ventilation system (4.1) and the personnel that is performing this heat treatment process is prevented from being subjected to said harmful gasses emitted due to said heat treatment.
- the invention is the production method of a heat-treated semi-finished fibre reinforced base fabric that has been produced by applying heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that has been used for carpet production, are fitted properly on the base.
- the process steps mentioned below are carried out in the above mentioned production method:
- the pressure is adjusted by moving the electrical heating cylinder (4.2) up and down via the air pressure pneumatic piston (4.3) according to the quality of the semi-finished fibre reinforced base fabric that is to be subjected to heat treatment.
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Abstract
The invention is related to electrical ironing mechanism that applies heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that are used in the production of a carpet by sewing said fibre yarns thereon, are fitted properly on the base and a heat-treated fibre reinforced base fabric production method that performs production with this mechanism.
Description
ELECTRICAL IRONING MECHANISM THAT APPLIES THERMAL TREATMENT TO THE SEMI-FINISHED FIBRE REINFORCED BASE FABRIC AND THERMAL TREATED FIBRE REINFORCED BASE FABRIC PRODUCTION
METHOD
Technical Field of the Invention:
An electrical ironing mechanism that applies heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that is used in the production of a carpet by sewing said fibre yarns thereon, are fitted properly on the base and a heat-treated fibre reinforced base fabric production method that performs production with this mechanism. Prior Art and Technical Problems that are Faced:
In the prior art, during the production of a base fabric that enables to produce a carpet by sewing fibre yarns thereon, after a muslin that is made of polypropylene and/or fibre material is spread over the base fabric, a pinning and fixing process is applied. Following this fixing process, the fibres are ragged and are distributed unevenly on the surface of the base fabric. After artificial turf and other similar material are woven on the base fabric having distributed and ragged fibres, a fixing process is carried out by using latex or other adhesive material. As the fibres on the base fabric are ragged, the latex or other similar adhesive applied thereon cannot be spread equally and homogenously over the entire surface. As a result, the durability of the base fabrics are reduced and as it is possible for all of the discharge holes of the base fabric to be covered with adhesive, the problem of insufficient discharging of rainwater is faced. In the case that the water cannot be discharged, the usage life of the carpet is reduced and the water that accumulates on the base fabric causes the carpet base to deteriorate in time. Due to these deteriorations, the players on the carpet may get injured.
Our utility model document numbered TR 2010 01641 Y can be given as reference to prior art documents. Our invention disclosed in this document is related to a base fabric that is used in carpets that are produced with the tufting technique and are mostly used in football field carpets, and the base texture of such carpets are formed by sewing fibre yams on these base fabrics. The base fabric produced by means of the production method mentioned in this document leads to humidity problems and thermal processing is not applied.
In the present art, in order solve the humidity problem encountered at the end of the production process of the fibre reinforced base fabric, the fabric is subjected to thermal treatment and following this the packaging process prior to shipment is started. However, when only thermal treatment is applied, the base fabric may be deteriorated due to heat and the homogenous structure of the base fabric can be disrupted. Moreover, the thermal treatment leads to expansion of the base fabric and due to this expansion, the thickness of the base fabric increases and the fabric is deteriorated, the heat subjected to the base fabric cannot be completely controlled and excess usage of thermal energy may be encountered.
Moreover, while fibre reinforcement is performed on this base fabric, as the packaging process is carried out before the humidity arising from production is not completely eliminated; it is possible to encounter problems such as the growth of bacteria and development of odour. The base fabric that has been produced by this method is stored in a warehouse until it is delivered to the delivery point or until it is applied onto the ground, and the fibre reinforced fabric gets damaged due to the bacteria and odour that is developed and the usage life is reduced. In the prior art, the humidity of the fibre reinforced base fabric cannot be removed. The locking ratio of the materials such as artificial turf that are woven onto this base fabric during the application of this fibre reinforced base fabric to the ground is low, and this reduces the resilience of the materials such as artificial turf located on the base fabric and it is, therefore, possible for materials such as artificial turf to fall out of the base fabric.
In order to solve such problems of the fibre reinforced base fabric having reinforced fibres on the surface that are non-homogenous and ragged, the base fabric is loaded between two cylinders that are heated and the unsmooth parts on the surface are ironed out and homogeneity is tried to be obtained on the fibre material located on the base fabric, and therefore, the technical problems caused by humidity are tried to be overcome.
In the prior art, the processes of subjecting the fibre reinforced semi-finished fabric can be
carried out in different methods. One of these methods is using lubricant heating and liquid heaters. In such systems, if an operator that is not experienced performs a wrong operation on the pressure control circuit that controls the pressure of the system, this may lead to a fire. Due to this reason, when the base fabric is subjected to heat treatment using lubricant heating and liquid heaters in order to avoid the problems mentioned above, the fabric needs to be controlled continuously during the entire production period. In such a heat treatment application, the cylinder that applies the heating process through which the fibre reinforced semi-finished base fabric passes contains materials such as oil or liquid. Moreover, this system must contain a liquid or oil discharge and reserve tank. The oil that is heated in the reserve tanks passes through the cylinders and enables the cylinders to heat up. As the liquid or oil contained in the reserve tank needs to continuously circulate, pressure is created and this pressure damages the system if any kind of security flaw is present. It is difficult to step in, as the oil used in this system is produced from petroleum. When water is poured over the burning oil, the fire cannot be put out and expensive fire extinguishing agents such as foam needs to be sprayed over the fire. Moreover, the usage lives of the lubricant systems that are used during heat treatment are lower in comparison to the electrical heating system subject to our invention. The oil that is used needs to be frequently changed in order to ensure that the system operates efficiently and this leads to an increase in production costs. Moreover, when oil is used in heat treatment applications, in case of any kind of breakdowns, it is difficult to intervene as the weight of the cylinder that is filled with oil is very heavy.
One of the heat treatment application methods in the production of fibre -reinforced base fabrics is the method of heating the cylinder that applies heat treatment with natural gas. Natural gas heats up the water or any other kind of material inside the cylinder the material in the form of water or gas that is heated is passed through the heating cylinder and heating of the cylinder is established. The semi-finished fibre reinforced base fabric that is received through the heated cylinder is subjected to heat treatment and the fabric is tried to be smoothed out and ironed. However, the natural gas heating systems must also have a liquid, gas or oil reserve tank and this leads to the above-mentioned problems.
In our invention, during the heating of the cylinders that carry out heat treatment in order to homogenize and smooth out the fibre located on the base fabric, heat treatment is applied by means of the heated cylinders that are heated by the transmission of electricity to the resistances that are located inside the tubes available inside the cylinder. The fibre reinforcement material located on the base fabric that is unevenly distributed and ragged is
smoothed out by means of heat treatment by being subjected to ironing.
In the prior heat treatment application systems, heat treatment was applied after the fibre type muslin that is covered over the base fabric is pinned for integration, without giving a break during production. This heat treatment was carried out in lubricant systems. When production is integrated on a line, a flow rate is present during production, and if undesired problems arise depending on this flow rate, such as the tearing off of the muslin or deformations occurring on the base fabric, the entire system needs to be stopped in order to intervene for repairs. When production stops, this leads to loss of efficiency and time and excessive energy and time needs to be used in order to increase the heat back to the level that is required for heat treatment. Moreover, when the production is stopped, the heat track needs to be completely moved back and following intervention the heat track needs to be brought back to its initial state and this takes up a lot of time. When the thermal process application section is integrated with the line, in case of a breakdown all of the lines need to be stopped. Production completely stops until the breakdown is repaired. Due to this reason in our invention, the heat treatment application process and the finishing process have been arranged such that it is not integrated with the line. By this means, in order to overcome a problem that is encountered at the heat treatment application section, the line does not need to be stopped before an ironing process and production prior to heat treatment is continued.
In the present system, after the fibre reinforced base fabric is produced, some problems that are dependent on production are encountered. When rolls are transferred from one place to the other, the edges of the rolls may be damaged. If such damage is not corrected, the seams may shift and production loss is encountered as the customers that purchase these rolls perform seam adjustments, the quality is reduced, and faulty products may be produced. Moreover, again depending on the winding problem, problems such as the fibre not being properly spread out can be faced. When the operator leaves his/her production post due to any reason, a second control needs to be carried out during ironing. The operator needs to carry out the adjustment process of adjusting the excess on the surface to the desired height without damaging the fibre or the base fabric by means of the surface adjuster available just before the ironing cylinder in order to overcome the uneven distribution or homogeneity problem of the fibre that may be faced during production. These problems cause reduction of the quality of the fibre reinforced base fabric that is produced.
Moreover, a ventilation system that is used to discharge the hazardous gasses created during the application of heat treatment in the prior art is not available. This causes the operator to
face life-threatening danger during heat treatment and the operator needs to be frequently distanced from this environment. In the mechanism of our invention, a ventilation system has been installed on the top section where heat treatment is applied on the fibre reinforced semi-finished base fabric and it is prevented for the operator to be subjected to chemicals that are discharged together with heat.
The fibre thickness on the semi-finished base fabric during production cannot be provided as the desired thickness every time. As fibre peaks may occur on the surface depending on this, this leads to production and quality losses. In our invention, a trimmer is used before the heat treatment in order to ensure that the different fibre thicknesses on the base fabric are equalized. For example, while the fibre thickness on the base fabric of the roll prior to the application of heat treatment needs to be 4 mm, in some sections they can be 7mm due to production errors. As the heat that is to be applied during the ironing of the base fabric that is to be subjected to heat treatment having fibre reinforcement at different thicknesses is fixed and as the heat to be applied to the 4mm fibre and the 7mm fibre is the same, homogeneity following ironing cannot be completely provided. A trimming mechanism has been developed that is used prior to ironing in our invention, in order to ensure that the fibre having different thickness on the base fabric is brought to the same thickness. The excess sections of the fibre thickness are trimmed by means of this trimming mechanism and the fibre thicknesses are equalized, as a result, equal heat treatment is applied to equal fibre reinforced thicknesses and homogeneity is provided following ironing, and higher quality reinforcement base fabric is produced.
The electrical heat treatment application mechanism of our invention is a mechanism that performs heat treatment in a separate area that is not integrated with the finishing system that is used after the fibre reinforcement containing muslin is covered and the finishing process is completed. As a result, the technical problems arising from the mechanism that performs heat treatment following the finishing system are overcome.
In our electrical heat treatment application mechanism of our invention, electrical resistance is used to heat the cylinders, instead of the liquid or oil heat treatment application mechanism that provides heat to the cylinders, therefore important advantages have been established in terms of security and costs. The mechanism that applies heat treatment to the fibre reinforced base fabric is simplified and the controlling of the heat treatment is made easier. If the heat treatment mechanism needs to be intervened for any kind of reason, it is ensured that intervention can be simple. In order to ensure this, instead of trying to repair
heavy cylinders that are filled with oil or liquid, the cylinder that has been heated with resistance is repaired. In our ironing mechanism subject to the invention having an electrically heated cylinder, the heating resistances are located inside the tubes that extend inside the cylinder. In case of a breakdown of the heating mechanism, it has been enabled for the intervention to be carried on the tube, by dismantling the tube that the resistance is located in without having to dismantle the cylinder.
In our invention, a mechanism has been placed on the roll that is available for heat treatment in order to solve the edge winding problems that are encountered on the roll, over which the fibre reinforced base fabric is wound and said mechanism can be moved in four directions being up-down, left and right. The control mechanism that can move in four directions has two opposite sensors and it transmits a signal to the control panel in order for the faulty part to be corrected. The problem of edge winding of the sections that are faulty in our invention is solved by moving the product to be subjected to heat treatment in the correct direction.
In order to remove the chemicals that arise during the application of heat treatment in our mechanism, a ventilation apparatus has been installed on the mechanism. As a result, the operators have been prevented from being harmed by these chemicals.
A trimming apparatus has been installed at the section before the heat treatment section in order to ensure that equal amount of heat is obtained from the cylinder, by bringing the thickness of the fibres located on the base fabric that has different thickness due to production faults, to equal thickness before the fabric is subjected to heat treatment. This trimmer is used in order to ensure that the different fibre thicknesses on the base fabric are equalized.
In our invention, while pressure is applied onto the base fabric that has equal fibre thickness in order to apply pressure according to the quality of the fibre reinforced base fabric an apparatus has been provided which enables upward and downward motion. This apparatus enables the cylinder that applies heat treatment onto the product to apply pressure at different angles and on different surface areas. By this means, the pressure is applied according to the quality of the fibre reinforced base fabric that is to be subjected to heat treatment and it is enabled for a higher quality base fabric production to be obtained.
Description of the Technical Drawings:
Figure- 1: Side plan view of the ironing system subject to our invention
Figure-2: Upper plan view of the ironing system subject to our invention
Figure-3: Right view of the ironing system subject to our invention
Figure-4: Left view of the ironing system subject to our invention
Figure-5: Front view of the ironing system subject to our invention Figure-6: Rear view of the ironing system subject to our invention
Figure-7: The view of the 1st condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention
Figure-8: The view of the 2nd condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention
Figure-9: The view of the 3rd condition of the decreasing and increasing contact surface with the heating cylinder of the fibre reinforced base fabric that is to be straightened out by ironing with the ironing system of our invention Figure- 10: Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition- 1)
Figure-11: Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition-2)
Figure- 12: Drawing and diagram of the winding correction system of the ironing system subject to the invention (Condition-3)
Figure- 13: Detailed view of the winding correction system of our ironing system subject to the invention
Figure- 14: Detailed view of the fibre trimming cylinder correction system of the ironing system subject to the invention Figure- 15: Detailed view of the electrical heating cylinder correction system of the ironing system subject to the invention
Brief definitions of the part numbers illustrated in the Figures:
1 -Semi-finished fibre reinforced base fabric roll expanding apparatus
1.1 Winding corrector piston
1.2 Winding corrector sensor 1.3 Semi-finished fibre reinforced base fabric roll
2- Fibre trimming apparatus transfer section of the semi-finished fibre reinforced fabric
2.1 Tension cylinder height adjustment lever
2.2 Tension cylinder prior to trimming
3- Fibre trimming apparatus of the semi-finished fibre reinforced fabric 3.1 Fibre trimming cylinder
3.2 Fibre trimming cylinder height adjustment lever
3.3 Fibre trimming apparatus tension cylinder
4- Electric heating apparatus of the semi-finished fibre reinforced fabric
4.1 Electrical heating apparatus ventilation system 4.2 Electrical heating cylinder
4.2.1 Chrome alloy heat cylinder
4.2.2 Heat system resistance rod
4.2.3 Resistor rod support table
4.2.4 Electrical heat cylinder shaft connection 4.2.5 Electrical heat cylinder shaft
4.3 Air pressure pneumatic piston (for electrical heating cylinder height adjustment)
4.4 Electrical heating system tension cylinder
4.5 Controller (electrical heating system) 5- Final product winding apparatus
5.1 Final product winding unit cylinder
5.2 Final product roll balancing weight 5.3 Final product roll
Detailed Description of the Invention:
An electrical ironing mechanism that applies heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that is used in the production of a carpet by sewing said fibre yams thereon, are fitted properly on the base and a heat-treated fibre reinforced base fabric production method that performs production with this mechanism.
The ironing mechanism subject to our invention where heat treatment is applied is installed in a different area than the sections where a muslin made of polypropylene and/or fibre material is spread over the base, pinning is performed and following this, the product is wound around a roll. Our mechanism is not installed right after the pinning section as opposed to the prior art.
The electrical ironing mechanism that applies heat treatment in our invention comprises, a fibre reinforced semi-finished base fabric roll expanding apparatus (1), a transfer section (2) that transfers the fibre reinforced semi-finished fabric to the trimming apparatus, fibre trimming apparatus (3) of the fibre reinforced semi-finished fabric, electrical heating apparatus (4) of the fibre reinforced semi-finished fabric, final product winding apparatus (5) and a ventilation section located on the opt section of the electrical heating apparatus.
In the mechanism subject to our invention, the fibre reinforced semi-finished base fabric roll expanding apparatus (1) comprises a winding corrector piston (1.1); a winding corrector sensor (1.2) and a semi-finished fibre reinforced base fabric roll (1.3). The faulty wound rolls (1.3) are sensed with the winding correcting sensor (1.2) and are corrected with the winding corrector piston (1.1). The roll (1.3) over which the semi-finished fibre reinforced base fabric is wound around, and the fabric is opened by means of the base fabric roll
expanding apparatus (1) for preparation before heating.
The fibre trimming apparatus transfer section (2) of the semi-finished fibre reinforced fabric of the mechanism subject to our invention comprises tension cylinder height adjustment lever (2.1), and a pre-trimming tension cylinder (2.2). By means of this section, the semi finished fibre reinforced fabric is prepared before the trimming process.
In the mechanism subject to our invention the fibre trimming apparatus (3) used for trimming the fibres of the semi-finished fibre reinforced fabric comprises a fibre trimming cylinder (3.1) a fibre trimming cylinder height adjustment lever (3.2), and a fibre trimming apparatus tension cylinder (3.3). The semi-finished fibre reinforced base fabric is brought to equal thickness prior to heat treatment by means of this invention and it is enabled for the fibres to receive an equal amount of heat from the heating cylinders.
In the mechanism subject to the invention, the semi-finished fibre reinforced fabric electrical heating apparatus (4) comprises an electrical heating cylinder (4.2) that consists of a chrome alloy heat cylinder (4.2.1), a heat system resistance rod (4.2.2), resistance rod support table (4.2.3), electrical heat cylinder shaft connection (4.2.4), and an electrical heat cylinder shaft (4.2.5). The heating cylinder (4.2.1) is preferably made of chrome alloy; however, it can be made of other materials. Additionally, an air pressure pneumatic piston (4.3) that adjusts the height of the electrical heating cylinder, an electrical heating system tension cylinder (4.4), and a controller (4.5) that controls the entire electrical heating system has been provided. Moreover, in the electrical mechanism of our invention, a ventilation system (4.1) that enables to discharge harmful gasses that are created, from the environment is provided at the top section of the electrical heating apparatus.
The mechanism subject to the invention also comprises a final product winding unit cylinder (5.1), a final product roll balancing weight (5.2) and a final product winding roll comprising a final product roll (5.3). In this section the finished fibre reinforced base fabric that has been de-humidified and ironed is wound again over the roll (5.3) in this section so that the fabric is ready for shipment.
A heating system resistance rod (4.2.2) where the electrical resistances that extend along the cylinder inside a tube is located is provided in the heating cylinder (4.2) of our heat treatment application mechanism of our invention. These resistance rods (4.2.2) heat up the heating cylinder (4.2) that shall subject the product to heat treatment. The heating system resistance rods (4.2.2) of our invention are mounted to the resistance rod support table
(4.2.3). The controller (4.5) used in our invention houses a temperature control circuit. This temperature control circuit enables heat treatment control.
The heat treatment application mechanism subject to our invention enables the smoothing process by applying pressure onto the fibre reinforced base fabric by means of a heating cylinder (4.2) that is heated via the electrical resistance rods (4.2.2). The amount of pressure to be applied onto the product and the angles of pressure is adjusted by means of the up and down motion of the cylinder (4.2). As a result, in the case that the product that has been subjected to heat treatment has a different quality, the quality of the final product is prevented from changing from one fabric to another by adjusting the pressure of the cylinder (4.2). The application of pressure at different angles by the cylinder (4.2) that is moved up and down is carried out by acting manually on the bottom section and by using the electronic controller. In the heat treatment mechanism subject to the invention, a pressure control circuit is available inside the controller (4.5) and the pressure amount to be applied onto the product is adjusted by said controller.
In our invention a mechanism has been placed on the roll that is available for heat treatment in order to solve the edge winding problems that are encountered on the roll, over which the fibre reinforced base fabric is wound, wherein said mechanism can be moved in four directions being up-down, left and right. The control mechanism that enables control is made by two opposite sensors (1.2). These sensors (1.2) transmit a signal to the controller (4.5) in order to correct the faulty section. The problem of edge winding of the sections that are faulty in our invention is solved by moving the product to be subjected to heat treatment in the correct direction.
In our invention, a ventilation system (4.1) is installed on the top section of the heat treatment section, in order to discharge the harmful gasses created during heat treatment application. The harmful gasses that emanate out during the application of the heat treatment is discharged by means of this ventilation system (4.1) and the personnel that is performing this heat treatment process is prevented from being subjected to said harmful gasses emitted due to said heat treatment.
The invention is the production method of a heat-treated semi-finished fibre reinforced base fabric that has been produced by applying heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that has been used for carpet production, are fitted
properly on the base. The process steps mentioned below are carried out in the above mentioned production method:
-placing the semi-finished fibre reinforced base fabric into the roll expanding apparatus
-transmitting the values detected by the winding correcting sensors (1.2) for evaluation, to the controller (4.5) after the semi-finished fibre reinforced base fabric roll is loaded onto the mechanism, in order to check if an edge winding problem is present in the roll (1.3) that is wound with the semi-finished fibre reinforced base fabric, and solving the problem of edge winding by transferring to the controller (4.5), the data received from the winding correcting sensors (1.2) that are located opposite each other in order to solve the problem of edge winding if such problem is present by moving the roll right-left and up and down,
-removing the excess fibre thickness of the semi-finished fibre reinforced base fabric whose winding problem has been solved, which has been received from the roll and that has a ragged surface by subjecting it to a trimming process - passing the semi-finished product that has been subjected to trimming in order to ensure that the fibres on the base fabric have equal thickness, through the electrical heating cylinder (4.2) and subjecting it to heat treatment and smoothing out the fabric by applying pressure onto the fibre surface located on the base fabric.
- winding the ironed semi-finished fibre reinforced base fabric around the roll (5.3) again, as a final product.
In our method of applying electrical heat treatment on the semi-finished fibre reinforced base fabric which comprises the above-mentioned process steps, additionally, the pressure is adjusted by moving the electrical heating cylinder (4.2) up and down via the air pressure pneumatic piston (4.3) according to the quality of the semi-finished fibre reinforced base fabric that is to be subjected to heat treatment.
Claims
CLAIMS:
1-An electrical ironing mechanism that applies heat treatment to the semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that are used in the production of a carpet by sewing said fibre yams thereon, are fitted properly on the base characterized by comprising a semi-finished base fabric expansion roll (1) onto which the fibre reinforced semi-finished base fabric is loaded, a transfer section (2) that transfers the semi-finished fibre reinforced base fabric to the fibre trimming apparatus, a semi-finished fibre reinforced base fabric fibre trimming apparatus (3), a semi-finished fibre reinforced base fabric electrical heating apparatus (4) and a final product winding apparatus (5).
2 An electrical ironing mechanism according to claim 1, characterized in that the electrical heating apparatus (4) of the semi-finished fibre reinforced fabric comprises, a heating cylinder (4.2.1) preferably made of chrome alloy, a heating system resistance rod (4.2.2) located inside the chrome alloy heating cylinder (4.2.1) and a controller (4.5) that controls the entire electrical heating system.
3 An electrical ironing mechanism according to claim 2, characterized in that the electrical heating apparatus (4) further comprises an electrical heating cylinder (4.2) that consists of resistance rod support table (4.2.3), an electrical heat cylinder shaft connection (4.2.4), and an electrical heat cylinder shaft (4.2.5).
4 An electrical ironing mechanism according to claim 2 and claim 3, characterized in that the resistance rods (4.2.2) located in the electrical heating cylinder (4.2) are disposed in the tube that extends along the cylinder.
5 An electrical ironing mechanism according to the preceding claims characterized in that it comprises an air pressure pneumatic piston (4.3) that adjusts the height of the electrical heating cylinder (4.2), and an electrical heating system tension cylinder (4.4).
6- An electrical ironing mechanism according to the preceding claims characterized in that it comprises winding correcting sensors (1.2) that sense if the winding of the semi-finished fibre reinforced base fabric over the roll (1.3) is faulty and that transmits the values that have been detected to the controller and a winding correcting sensor (1.1) that enables to move the roll (1.3) in order to correct the winding when it is decided that a winding fault is present.
7- An electrical ironing mechanism according to the preceding claims characterized in that it comprises a fibre trimming apparatus transfer section (2) that trims the fibres of the semi finished fibre reinforced fabric, having a tension cylinder height adjustment lever (2.1), and a pre-trimming tension cylinder (2.2).
8- An electrical ironing mechanism according to the preceding claims characterized in that it comprises a fibre trimming apparatus (3) having a fibre trimming cylinder (3.1) that ensures the equal distribution of heat from the heating cylinders by ensuring that the semi-finished fibre reinforced base fabric is brought to equal thickness before the heat treatment application, a fibre trimming cylinder height adjustment lever (3.2), and a fibre trimming apparatus tension cylinder (3.3).
9- An electrical ironing mechanism according to claim 5, characterized in that it comprises a pressure control circuit that is located inside the controller (4.5) that is used to adjust the amount of pressure to be applied onto the semi-finished product.
10 An electrical ironing mechanism according to the preceding claims characterized in that it comprises a final product winding unit cylinder (5.1), a final product roll balancing weight (5.2) and a final product winding roll (5.3) comprising a final product roll.
11-An electrical ironing mechanism according to the preceding claims characterized in that it comprises a ventilation system (4.1) that is installed on the top section of the heat treatment section, in order to discharge the harmful gasses created during heat treatment application.
12. An electrical ironing mechanism according to the preceding claims characterized in that it comprises it is installed in a different area than the sections where muslin made of polypropylene and/or fibre material is spread over the base, where pinning is performed and following this where the product is wound around a roll.
13. The invention is a method of applying heat treatment on a semi-finished fibre reinforced base fabric in order to ensure that the ragged fibres located on the surface of the fibre reinforced semi-finished base fabric that is used in the production of a carpet by sewing said fibre yarns thereon, are fitted properly on the base; characterized in that said method comprises the steps of;
- placing the semi-finished fibre reinforced base fabric into the roll expanding apparatus
- passing the semi-finished product that has been subjected to trimming in order to ensure that the fibres on the base fabric have equal thickness, through the electrical heating cylinder (4.2) and subjecting it to heat treatment and smoothing out the fabric by applying pressure onto the fibre surface located on the base fabric.
- winding the ironed semi-finished fibre reinforced base fabric around the roll (5.3) again, as a final product.
14 A method of applying heat treatment on the semi-finished fibre reinforced base fabric according to claim 13, characterized in that it comprises the step of transmitting the values detected by the winding correcting sensors (1.2) for evaluation, to the controller (4.5) after the semi-finished fibre reinforced base fabric roll is loaded onto the mechanism, in order to check if an edge winding problem is present in the roll (1.3) that is wound with the semi finished fibre reinforced base fabric, and solving the problem of edge winding by transferring to the controller (4.5), the data received from the winding correcting sensors (1.2) that are located opposite each other in order to solve the problem of edge winding if such problem is present by moving the roll right-left and up and down.
15 A method of applying heat treatment on the semi-finished fibre reinforced base fabric according to claim 13, characterized in that it comprises the trimming of excess fibres by subjecting the semi-finished fibre reinforced base fabric having a ragged surface, received from the roll after the semi-finished fibre reinforced base fabric roll is loaded onto the mechanism, to a trimming process in order to equalize the fibre thickness prior to heat treatment.
16 A method of applying heat treatment on the semi-finished fibre reinforced base fabric according to claim 14, characterized in that it comprises the trimming of excess fibres by subjecting the semi-finished fibre reinforced base fabric having a ragged surface, whose winding problem has been solved, and which has received from the roll after the semi finished fibre reinforced base fabric roll is loaded onto the mechanism, to a trimming process in order to equalize the fibre thickness prior to heat treatment.
17 A method of applying heat treatment on the semi-finished fibre reinforced base fabric according to claim 13, claim 14, claim 15 or claim 16 characterized in that it comprises the pressure amount adjustment step, by moving the electrical heating cylinder (4.2) up and
down, via the air pressure pneumatic piston (4.3) according to the quality of the semi finished fibre reinforced base fabric that is to be subjected to heat treatment.
18 A fibre reinforced base fabric produced as a result of the application of heat treatment onto the semi-finished fibre reinforced base fabric described in claim 13, claim 14, claim 15, claim 16 or claim 17.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR201921031 | 2019-12-22 | ||
| TR2019/21031 | 2019-12-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2021133287A1 true WO2021133287A1 (en) | 2021-07-01 |
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ID=76574888
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2020/050165 WO2021133287A1 (en) | 2019-12-22 | 2020-02-29 | Electrical ironing mechanism that applies thermal treatment to the semi-finished fibre reinforced base fabric and thermal treated fibre reinforced base fabric production method |
Country Status (1)
| Country | Link |
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| WO (1) | WO2021133287A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB979018A (en) * | 1961-06-12 | 1965-01-01 | Mount Hope Machinery Ltd | Roll with means for eliminating longitudinal curvature |
| EP0267604A2 (en) * | 1986-11-13 | 1988-05-18 | QST Industries, Inc. | Waistband interlining with thin edges and its ultrasonic formation |
| CN203768665U (en) * | 2014-03-05 | 2014-08-13 | 苏州博杰思达机械有限公司 | Ironing roll for ironing machines |
| CN208136421U (en) * | 2018-03-15 | 2018-11-23 | 安美桥（南宫）羊绒制品有限公司 | Cashmere fabric assembly line |
| CN208603445U (en) * | 2018-04-28 | 2019-03-15 | 长兴宝福织造股份有限公司 | Cotton measures wrap-up |
-
2020
- 2020-02-29 WO PCT/TR2020/050165 patent/WO2021133287A1/en active Application Filing
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB979018A (en) * | 1961-06-12 | 1965-01-01 | Mount Hope Machinery Ltd | Roll with means for eliminating longitudinal curvature |
| EP0267604A2 (en) * | 1986-11-13 | 1988-05-18 | QST Industries, Inc. | Waistband interlining with thin edges and its ultrasonic formation |
| CN203768665U (en) * | 2014-03-05 | 2014-08-13 | 苏州博杰思达机械有限公司 | Ironing roll for ironing machines |
| CN208136421U (en) * | 2018-03-15 | 2018-11-23 | 安美桥（南宫）羊绒制品有限公司 | Cashmere fabric assembly line |
| CN208603445U (en) * | 2018-04-28 | 2019-03-15 | 长兴宝福织造股份有限公司 | Cotton measures wrap-up |
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