WO2021251917A1

WO2021251917A1 - Peice dyeing and drying technique of textile products by means of an ecological process in a single machine

Info

Publication number: WO2021251917A1
Application number: PCT/TR2020/050798
Authority: WO
Inventors: Beytullah ULAS
Original assignee: Ug Tekstil Tasarim Arge Uretim Ith. Ihr. Paz. San. Ve Tic. Ltd. Sti.
Priority date: 2020-06-12
Filing date: 2020-09-03
Publication date: 2021-12-16
Also published as: EP4073311A4; EP4073311A1

Abstract

The invention is related to a textile machine and a chemical process that is to be used in the textile ready-wear sector, for dyeing and drying of textile products with minimum amount of water in a single machine using special breakwaters, nozzles and infrared heating systems.

Description

PEICE DYEING AND DRYING TECHNIQUE OF TEXTILE PRODUCTS BY MEANS OF AN ECOLOGICAL PROCESS IN A SINGLE MACHINE

TECHNICAL FIELD OF THE INVENTION

KNOWN STATE OF THE ART (PRIOR ART)

The textile dyeing sector has rapidly increased research and development due to the attention to processes and innovations that provide an environmentally friendly solution, as the awareness regarding sustainability and environment has increased nowadays. Every company, brand, R&D center in the textile sector, is trying to develop various methods in order to minimize the pollution that is created particularly during the textile finishing and dyeing processes. Due to this reason, developments in textile piece dyeing machine sector have been increasing day by day.

The prior art machines used for textile piece dyeing are washing machines that are aimed only for dyeing. Nowadays there are several piece washing-dyeing machines. Generally these machines comprise dyeing stations that that operate at various revolutions and that have a wider width between the inner and outer drum as they are developed for high water consumption, and they have a drum that contains metal breakwaters, a perforated, triangular structure, and said machines are operable with vapor and electricity and can be controlled manually or by a computer.

Several steps are applied to carry out the dyeing process. Said processes are; pre-processing, dye bath, rinsing, acid rinsing, hot washing, cold washing, fixation phase, rinsing, foaming, re-rinsing, enzyme washing, softening, wringing, and drying. Until all of these steps are completed, the products have to go through many machines because all of these machines have their own specific tasks, for example, the washing-dyeing machine where the dye bath is made is separate from the dryer used for drying the products. Due to this reason, the dyed products are delivered to separate machines for required processes such as drying, rinsing or wringing.

Moreover said systems include water discharge (waste water discharge). The dyeing carried out with conventional processes and machines, have been able to reduce dyeing to a minimum of 1:5 (5 litres of water for 1kg) flotte, several steps of application and the flotte ratios of each of these steps are minimum 1:5 (51t for 1 kg) and due to this reason, the waste water discharge reaches up to high amounts. Moreover as each step also increases the number of chemicals used, the damage to the environment also increases. It is a known fact that these waste waters that contain chemicals that lead to hazardous environmental effects which can disturb the balance of nature.

In textile dyeing processes, nowadays, in order to dye 100 kg of products, the following average consumption is carried out; 2750-9000 It water, 75 kwh energy, minimum 200 minutes of time, 2 or 3 machines (comprises dyeing, wringing and drying steps) and at least 3 personnel. At the same time, for the process of giving an effect, 500 It water, 20kwh energy, 90 minutes of time, 3 personnel and 3 machines (comprises, giving an effect, rinsing and drying steps) need to be used for a 100 kg product.

Nowadays textile machines that provide water, chemical and energy savings are available. Some of these machines have a spraying method that provides a similar, although not the same, function to the machine of our invention. However the spraying method of these machines are used in conventional water processes having a flotte ratio of 1:5. It has to be noted that these flotte ratios have been given only for dyeing liqueur rates and that they do not include the liqueur rates of the process steps following the dyeing process. The reason for this is that the water and chemical ratios used in machines significantly vary.

This invention is also directly related to the patent application dated 01.10.2019 numbered PCT/TR2019/050813 and several developments have been carried out in relation to the subject matter of the invention. The nozzle system used in the application numbered PCT/TR2019/050813 of the prior art, cannot carry out the proper and homogenous distribution of the solution to products. Infrared heating systems are required in order for the process to be carried out smoothly and to create the medium that contributes to the bonding of the dye covalently with fibre. At the same time valve systems that enable to create the medium that supports reactions which increase the fixation percentage and attraction force of the dye to the fibre and enables the stable continuation thereof are required.

As it has also been mentioned above, the processes applied at the dyeing and finishing steps (bleaching (pre-finishing), dyeing (coloring, press), and chemical finishing (finishing)) in the textile sector are severely hazardous to the environment. Nowadays the reduction of these damages and creating sustainable solutions has gained significant importance. Within this context, machine processes and a sustainable and environmentally friendly textile machine that enables easy dyeing, and drying of textile products, that has low water consumption and saves energy in order to support and serve the Sustainable Development Goals and realize the commitment requested by Global Environmental Organizations from global brands is required.

BRIEF DESCRIPTION OF THE INVENTION AND ITS AIMS

The present invention is related to a textile machine and chemical process for dyeing and drying of textile products with minimum amount of water in a single machine using a special breakwater, nozzle and infrared heating systems that meet the above mentioned requirements and eliminates the disadvantages and brings about some additional advantages.

All of the developments carried out according to the prior art in terms of machinery and chemicals, are developments carried out to chemically and mechanically strengthen the covalent bond of the process with the fibre, to increase the minimum level of the dyeing process reactions, attraction and fixation rates to maximum and to keep these rates at a maximum level and to provide an ideal product that is compliant with standards.

The machine system and the chemical process of the invention provides 97% water consumption reduction, 90% lower chemical usage and 80% more energy saving.

The invention enables both the dyeing and drying of textile products at the same time (in a single machine with a single process). Therefore it provides energy and time saving.

In the textile machine of the invention, “s” shaped breakwaters that have a special sinus shape are provided within the perforated stainless steel drum structure. The “s” and sinus structure of these breakwaters, enable products to be mixed inside the drum without breaking and they enable the fibres of the products to absorb the dye, and they contribute to the friction of the products, therefore significantly aiding in the homogenous attraction and the bonding of the dye. At least two nozzles have been provided in these breakwaters. The systems that are used for the nozzles to deliver solutions and for spraying have been specifically designed. These nozzles enable the solution to be sprayed by pressure onto the products in a single step by means of the pump. The products absorb the entire solution during dyeing and the solution bonded to the fibres, therefore leaving it damp. Moreover after the products absorb the entire solution, the remaining dye, vaporizes during the solution and water drying process. By this means, a discharging process is not required. Even though in some cases the usage of a discharging system in the machine shall not be necessary, a discharge system has still been added to the machine. In solutions in which high percentage dye is used, the bonding of the dye to fibres is difficult due to the chemical structure of the dyes. Due to this reason increase in the amount of solution and water may be required or a minimum of 1 time rinsing with water may be required in accordance with the process. This is necessary in order to meet the conditions of fastness tests. In such cases again waste water is produced although it has less chemical content in comparison to the chemicals and waste water amounts in conventional systems.

In conventional methods, the most important problem encountered, particularly when reactive dyeing is being carried out, is the condition of hydrolysis which negatively effects the reaction of the dye with the hydroxyl groups in the fibre. The reaction dye reacts with fibres due to its chemical content and at the same time, it reacts with the hydrogen in water and this leads to hydrolysis or in other words dye remnants that were not bonded with the fibre. The higher the liqueur amount, the higher the hydrolysis rate shall be. The extra processes such as the hot and cold washes that are conducted following the dyeing processes, are also carried out to remove the nonfixed dye called hydrolysis from the product. As the invention creates a medium where very little water is used during the chemical process, this reduces the risk of hydrolysis to a minimum. This non-aqueous medium is only possible by the combination of the chemicals used, enabling the correct reaction between the related products and by obtaining a strong fixation degree. Therefore, extra washing-rinsing processes are not required for meeting the desired fastness standards.

By means of the chemical process and the machinery system, the agents such as reactives, pigments, colorants and direct dyestuff are dyed and dried in the same medium in the machine and the product is taken out of the machine as a ready product. Therefore significant decrease is experienced in the water and chemical amounts used.

In order to control and provide optimum temperatures determined according to the dyestuff and processes used in the invention infrared heat resistors have been used and therefore it has been enabled for the drum to be easily heated and for the heat to be controlled.

The problem of environmental damage has been minimized as the machinery system of the invention creates no discharge during low and medium level amounts of dyeing and minimum level of waste water in high amounts of dyeing, and as it also has low energy consumption, the system of the invention is an environmentally friendly system. Moreover the number of machines and personnel used to carry out the processes are also reduced.

A homogenous distribution has been provided together with the nozzle system that is used. A shaft system has been developed which enables the nozzle system to reach the drum.

At the same time, as a difference to the prior art, breakwater forms have been developed which enable the continuation of the homogenous dyeing of the products and for the dye to be spread smoothly.

The invention provides a sustainable and environmentally friendly solution to the sector. As both the production and the consumption values are very low in comparison to conventional processes it has great contribution to the industry.

Definition of the Figures of the Invention

The figures that are used to further describe the piece dyeing and drying technique of textile products without an aqueous system, using a spray technique in a single machine that has been developed by means of this invention is as follows:

Figure 1 is the general view of the dyeing machine

Figure 2 is the view of the breakwater

Figure 3 is the view of the rotating connector

Figure 4 is the view of the infrared heater

Figure 5 is the view of the valve

Figure 6 is the general view of the machine

Figure 7 is the view of the shaft

Figure 8 is the view of the nozzle

Figure 9 is the view of the heating coil

Figure 10 is the view of the drum.

Definitions of the aspects and parts that form the invention

The parts of the piece dyeing and drying technique of textile products without an aqueous system, using a spray technique in a single machine that has been developed by means of this invention have each been numbered and the references of each number has been listed below.

1 Machine

2 Drum 3 Breakwater

4 Nozzle

5 Shaft

6 Heating coils

7 Valve System

8 Computer panel

9 Heating Resistor

10 Rotating Connector

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description the novelty subject to the invention has been described for further clarification of the subject with illustrative examples that shall not limit the scope of the invention.

Figure 1 shows the general view of the dyeing machine, figure 2 shows the view of the breakwater (3), figure 3 shows the rotating connector, figure 4, is the view of the infrared heater, figure 5 shows the valve system (7), figure 6, is the general view of the machine, figure 7 is the view of the shaft (5), figure 8 is the nozzle (4), figure 9 is the view of the heating coil (6), figure 10 is the view of the drum (2).

The textile machine (1) that enables to dye and dry textile products at the same time comprises, a drum (2) into which the products are placed, an “s” shaped breakwater (3) that enables the products inside the drum to be properly mixed and the dye to homogenously be distributed and absorbed, at least a nozzle (4) located inside the breakwaters and the rear mirror of the drum, that enables the solution to be sprayed by pressure onto the products in a single step by means of a pump, a shaft (5) that ensures that the nozzle (4) is safely delivered to the breakwaters (3), a heating coil (6) that provides the inlet and outlet of hot air, a valve system (7) that guides the water to be discharged without damaging other parts when any kind of water discharge is required and that prevents the loss of humidity and heat that are generated in the drum and are necessary for reaction, a computer panel (8) that enables the process to be manually and automatically controlled, at least an infrared heater resistor (9) located inside the drum (2), that is insulated against possible external factors in order for optimum temperature to be provided and controlled and a rotating connector (10) attached to the end of the shaft (5). Moreover a heat probe system that enables to control heat that passes through the shaft (5) and is located inside the drum, a rotating connector (10) at the end of the shaft, an electromechanic device within the electromechanic system that enables power and signal transmission for temperature data to be delivered to the panel, a pump that enables the solution that is being mixed inside the reactor to be delivered to the nozzles and a valve have also been provided.

In prior art, in order to dye 1 kg of textile products, 90 It of water, 0,83 kwh energy, minimum 200 minutes of time, 3 machines (comprises dyeing, wringing and drying steps) and at least 3 personnel is used in the conventional methods and aqueous mediums. The machine of the invention however reduces these numbers by carrying out the chemical process in minimum 110 minutes, maximum 21t water, 0.15 kwh energy, 1 machine and 1 personnel and thereby it provides significant saving.

The comparison by percentage of the factors of water, chemicals, energy and time used in conventional methods and the machine of the invention, and the reduction amount by percent provided by the machine of the invention in comparison to classical methods have been shown in Table 1.

Table 1 : Comparison of the prior art and the invention*

* The data has been calculated over maximum values for the method of the invention and the conventional method present in industry. The values have been obtained from the LCA (life cycle assessment) data. The study from which said data were obtained was conducted in compliance with ISO 14040 and ISO 14044 directives. For the values for the study life cycle assessment (LCA), the production data of 2019 for Retune dyeing process that has been developed by U&G Textile have been taken as basis. The evaluation of the life cycle has been modelled with the Simapro 9.0 LCA package of the Ecoinvent database. Local data have been used for vapor and water during life cycle assessment. These localized data, are also available in the Turkish Life Cycle Database.

By means of the solution and the machinery system used in the invention, the solution is homogenously distributed between the fibre and the fabric and thereby homogenous dye delivery is performed. By this means, the amount of water and chemical usage is reduced.

In the inventive process that enables to carry out the dyeing, drying and softening processes using the textile machine (1) of the invention, first of all the product is loaded into the machine, and the solution is added into the reactor of the machine that is 1.4 to 2 times more by weight (for products whose colour has been determined min 001%-max 20%, this may vary according to the weight and type of fabric) of the textile product. The solution contains dyestuff that is dissolved in water, levelling agent that contains a chipping preventer and wetting agent, a chemical that has ion immobilizing features and that prevents the rapid processing of alkaline thereby preventing the striking of alkali and formation of abrage, a chemical that prevents the degradation of chemicals, reactive dyeing levelling agent (wetting agent, chipping preventer, leveller, pH regulator, ammonium sulphate content) and salt and this mixture is continuously mixed in the reactor. The content of this solution may differ according to the contents of the fabric. For this reason a second method application has been developed. The solution is applied onto the products primarily without the dyestuff but with the above mentioned chemicals therein. After the products absorb the chemicals, the dye is delivered to the products.

The process can be both manually and automatically controlled by means of the computer panel (8) located on the machine (1). During this process, the products that are dry and are ready to be dyed start to rotate inside the drum at low speed (20 min/revolution).

The infrared heat resistors (9) that are located around the drum in order to safely control and provide optimum temperatures determined according to the dyestuff and processes used in the invention put into use. These heat resistors (9) are mounted such as to cover the periphery of the external drum and they have been insulated against possible external factors. When the temperature mode is between 30°C -60°C in accordance with the dye and process used, the pumps and valves are activated. The solution that is being mixed inside the reactor by means of the pump, is delivered to the at least two nozzles (4) that are located inside the special “s” shaped breakwaters (3). The systems of these nozzles (4) within the machine (1) have been specifically designed. The shaft (5) that is connected to the rear section of the drum (2) which also connects the drum to the chassis and passes through the middle of the bearing, is perforated by a special technique and thereby it allows all systems to pass through this shaft (5) and enables them to reach the breakwaters (3) safely and reliably even if the drum is rotating at a very high speed. Inside the shaft (5) the heat probe that enables temperature control, which is located in the drum (2) is provided. A rotating connector is available at the end of the shaft (5) and an electromechanic device within the electromechanic system that enables power and signal transmission for temperature data to be delivered to the panel has been provided.

The solution is sprayed with pressure onto the products located inside the machine (1) via said nozzles (4). The products absorb the solution that is received from the nozzles (4) after some time, they also cause friction by means of the mixing feature of the “s” shaped breakwaters (3) and they homogenously distribute the solution among themselves. After the products absorb the entire solution within the medium the valve and the pump is disabled. At this stage, if dye is not present in the solution, after the products absorb the solution containing auxiliary chemicals (after 20 minutes max.) the dye is added with the same system.

The products are rotated in a drum for 0-20 minutes, for at least 20 minutes/revolution by changing direction from right to left at a determined temperature (minimum 30 degrees, max. 100 degrees). This temperature and application time, enable the solution to bond with fibres and protect products. The rotation speed of the machine (1) may vary as minimum 10 min/revolution and maximum 400 min/revolution.

Following this alkali is added to one of the solution tanks. The addition of alkali is carried out in order to form the necessary pH value in order to increase the attraction percentage and the covalent bonding to the fibres by the dye located in the solution that is applied to the products. In conventional methods, alkali is used for the same purpose. The addition of alkali can vary according to the colour of the product, and light soda, carbonate, bicarbonate, caustic, aluminium sulphate, trisodium phosphate can be used. At the 30th or 40th minute of the process, the valve and the pump are activated and the alkali addition is sprayed onto the products via the nozzles (4). During this time, the pH value of the products must be between 10-12. The medium is fixed to the range of 50-60 degrees and the products continue to rotate in the drum (2) for 30-60 minutes. Following this, the infrared heaters (9) are inactivated and the acid addition is made to one of the tanks such that the pH of the products is 5.5. The acid (the acid used may vary according to colour, such as formic acid, acetic acid, neutral acid and hydraulic acid)is sprayed over the products by the activation of the valve and the pump and the products continue to rotate inside the drum (2) for 10 minutes. Following this a fixator shall be added into one of the solution tanks in order to fix the dye that is not bonded with the wetting agent assisted cationic fixator. The route of the solution that is delivered from the tank containing the fixator is separate from the system of the other chemicals. The fixator is delivered to the drum via the valve and the pump, however the assembly line of the other chemicals are not used. The reason for this is to prevent the negative effects encountered in systems such as the negative effect of the solution that remains or may remain in the systems where other chemicals are used on the reaction of the fixator and other negative effects such as not being able to provide homogeneity and leading to abrage or stains when sprayed on products. This system again passes through the shaft and is delivered to the nozzle located at the rear mirror of the drum and is sprayed onto the products at high pressure (2-8 bars). After this process the products continue to rotate in the drum (2) for 10 minutes. If dyeing at a high percentage rate is carried out, at this step, rinsing is carried out by taking maximum 21t of water per 1kg of products from the water tank that is located inside the machine. If medium or low percentage dyeing is being carried out a rinsing process is not required and discharging waste water is not necessary. Following this, silicon (conditioner) is added in order to ensure that the touch of the products is soft. The valve and the pump are activated and the silicone is sprayed onto the products via nozzles (4). After 5 minutes the heating coils (6) are activated and the drying step of the products is started. Although this time varies according to the type and content of the fabric, this process may continue for min. 30- max. 60 minutes. The specifically designed valve systems (7) located on the dust chamber and below the drum (2) and the heating coils (6) can also be controlled manually or automatically via the computer panel. When the heating coil (6) is activated, the valve located below the coil is opened and the inlet and outlet of hot air is provided. These valves (7) are closed during dyeing; and they prevent the output of vapor from the openings of the bottom and top valves and this also negatively effects dyeing performance. The valve (7) located on the region where the dust chamber and the hot air discharge is located, prevents the infiltration of liquids from the drum into the dust chamber and the filter and if required it enables to collect and direct the liquid therein to be discharged, thereby providing protection against any problems. The valve system (7) is the system that prevents the loss of humidity and heat that is required for reaction and is created in the drum, and it enables to direct the water to be discharged if any kind of water discharge is required, without harming the other parts.

After the drying step is concluded, the machine shuts itself off and the products are ready to be checked and packaged. In the conventional prior art, 12 different processes are required for fixing the dye to the fabric. The differences of the process steps can be seen in the comparison table (Table 2). As the process of the invention is brief, the perforation, wearing, tearing, twisting, and deformation risks of the fabric is significantly eliminated and therefore these risks are reduced at an average of 90% in comparison to the prior art. The dye raw material groups used are reactives, colorants, pigments, thermochromic, photochromic etc. Some these are the same with the dye groups used in traditional methods.

In the system developed by means of the present invention the method of dyeing the textile comprises the following process steps:

• Placing the textile product and the solution that is 1.4 times to 2 times the weight of the product into the reactor of the machine.

• Rotating the products that are dry and are ready for dyeing inside the drum (2),

• Determining the process steps according to the contents of the product and applying the solution onto the products that contains the dye or applying the auxiliary chemicals that do not contain the dye to the products beforehand and then adding the dye,

• Activating the infrared heat resistors (9) in order to control and provide the required temperatures, • Activating the pump and the valves when the temperature is between 30°C - 60°C,

• Delivering via the pump, the solution passing through the rotating shaft (5) of the system to the at least one nozzle (4),

• Spraying the solution via at least one nozzle (4) onto the products that are located in the machine,

• Dyeing of the products by friction by means of the characteristics of the breakwater (3),

• Inactivating the valve and the pump,

• Spraying the alkali solution via at least one nozzle (4) onto the products that are located in the machine,

• Spraying the acid via at least one nozzle (4) onto the products that are located in the machine,

• Spraying the cationic fixator assisted with a wetting agent via at least one nozzle (4) onto the products that are located in the machine,

• Carrying out the rinsing process by taking maximum 21t of water per 1kg of products from the water tank that is located inside the machine,

• Spraying the silicone via at least one nozzle (4) onto the products that are located in the machine in order to ensure that the products are soft to touch,

In the system developed by means of the present invention the method of drying the textile comprises the following process steps:

• Activation of the heating coils (6),

• Adjusting the heating coil (6) to a certain temperature in accordance with the type and weight of the fabric,

• Enabling the inlet and outlet of hot air by the opening of the valve system (7) that is located below the heating coil (6),

Table 2: Comparison of the process steps

Claims

1. A textile machine in which the drying and dyeing of textile products are carried out together characterized by comprising; an “s” shaped breakwater (3) that enables the products inside the drum to be properly mixed and the dye to be homogenously distributed and absorbed, at least a nozzle (4) located inside the breakwaters and on the rear mirror of the drum, that enables the solution to be sprayed by pressure onto the products in a single step by means of a pump, a shaft (5) that ensures that the nozzle (4) is safely delivered to the breakwaters (3), a heating coil (6) that provides the inlet and outlet of hot air.

2. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising a valve system (7) that prevents the loss of humidity and heat that is required for reaction and is created in the drum, and enables to direct the water to be discharged if any kind of water discharge is required, without harming the other parts.

3. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising a computer panel (8) that enables to control the process manually and automatically.

4. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising at least an infrared heater resistor (9) located inside the drum (2), that is insulated against possible external factors in order for optimum temperatures to be provided and controlled.

5. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising a heat probe system, that is located inside the drum and that passes through the shaft (5), to control the temperature.

6. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising a rotating connector (10) at the end of the shaft and an electromechanic device that enables power and signal transmission to the panel for temperature data.

7. A textile machine in which the drying and dyeing of textile products are carried out together according to claim 1, characterized by comprising a pump and a valve that enable the solution that is being mixed in the reactor to be delivered to the nozzles.

8. A method for dyeing textile products in a textile machine characterized by comprising the following process steps;

• placing the textile product and the solution that is 1.4 times to 2 times the weight of the product into the reactor of the machine,

• activating the infrared heat resistors (9) in order to control and provide the required temperatures,

• activating the pump and the valves when the temperature is between 30°C - 60°C,

• dyeing the products by friction by means of the features of the breakwater (3),

• inactivating the valve and the pump,

• spraying the silicone via at least one nozzle onto the products that are located in the machine in order to ensure that the products are soft to touch.

9. A method for drying textile products in a textile machine characterized by comprising the following process steps;

• activation of the heating coils (6),

• enabling the inlet and outlet of hot air by the opening of the valve system (7) that is located below the heating coil (6).

10. Textile machine operation method in which the dyeing processes of the textile products are carried out according to claim 8, characterized in that the at least one alkali solution that is sprayed over the products via the nozzle (4) is selected from the group consisting of light soda, or carbonate or bicarbonate or caustic or aluminium sulphate or trisodium phosphate.

11. Textile machine operation method in which the dyeing processes of the textile products are carried out according to claim 8, characterized in that the valve and the pump are activated and the at least one acid that is sprayed over the products is selected from the group of formic acid, or acetic acid or neutral acid or hydraulic acid.