Patent Application
20180230634
The underlying concepts, but not necessarily the language, of the Indian provisional patent application number. 3002/MUM/2015 filed on Aug. 8, 2015 from which this application claims benefit of priority is incorporated in this specification by reference. The above referred patent application and contents as disclosure therein are made part of this specification and are treated as if disclosed in their entirety in this specification.
The subject matter generally relates to an apparatus for textile processing and method manufacturing the apparatus. More specifically, the subject matter relates to an apparatus method of manufacturing the apparatus for impregnation of fluids and chemical into yarn and/or textile and/or fabric.
Over a period of time yarns used in textile industry have become finer, denser, stronger and with less hairiness. Denser and stronger yarns can now withstand stressed environment of weaving machines. Yarns are applied with the bonding chemical and/or synthesized and/or natural starch to make them strong enough to withstand stresses of high speed weaving preparatory and weaving machine. This has not only resulted in increased speed of production of textile, but also made possible to increase density of the textile. Both, the yarn and the textile thereof have become so dense that intra-yarn space, i.e. space within yarn and inter-yarn i.e. space in between adjacent yarns, have considerably reduced. Reduced inter-yarn and Intra-yarn spaces are desirable for a number of reasons, such as fine finish and otherwise improvement in other qualities. At the same time, it also limits absorption capacity of yarn and the textile thereof. Limitation on the absorption capacity of the yarn and the textile is undesirable in course of textile processing. A number of processes often get adversely affected by reduced absorption capability of a yarn or textile. Such processes include wet processing such as singeing, de-sizing, bleaching, mercerizing, dyeing, and washing etc. A number of techniques for increasing the absorption capacity of yarn and the textile have been applied by the industry. However, these techniques are either technology intensive, expensive, less-commercially viable or have problems relating to scaling from laboratory conditions to the industry conditions. Patent documents relating to the Numbers EP 0 969 131 A1, U.S. Pat. No. 3,688,527, and WO99/37844 show some solutions which are discussed in more details with reference to subject matter at the end of the specification.
Therefore, an apparatus is desirable that addresses the above problems. The subject matter provides solution to the above and other problems.
According to one aspect the subject matter provides an apparatus comprising: a first transducer, wherein the first transducer is adapted to transmit ultrasonic waves of a first wavelength into a first tank, and the first tank is configured to establish a substantially standing ultrasonic wave pattern of the ultrasonic waves inside the first tank; and a disposer adapted to dispose a textile into the first tank at a first distance from the first transducer, wherein the first distance is determined based the first wavelength. In one embodiment the first transducer and geometry of the first tank are configured to expose the textile to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2. In a second embodiment, the first transducer and geometry of the first tank are adapted to transmit at least 8 watts/liter of ultrasonic power into the first tank. In a third embodiment, the apparatus is configured to operate on a sweep frequency of ultrasonic waves, the sweep frequency is a band of frequencies around a first frequency, wherein the first frequency corresponds to the first wavelength and the disposer is configured to dispose the first textile at the first distance, the first distance is determined based on the first frequency. In a fourth embodiment, the disposer comprises a first plurality of rollers and the first plurality of rollers are adapted to dispose multiple iterations of the textile through the first tank and each iteration of the textile is separated from adjacent iteration of the textile by a distance, wherein the distance is determined based on the first wavelength. In a firth embodiment, the disposer disposes each of the iterations of the textile at locations that corresponds to locations of antinodes of the substantially standing ultrasonic wave pattern formed in the first tank. In a sixth embodiment, the apparatus comprises a second transducer, wherein the second transducer is adapted to transmit ultrasonic waves of a second wavelength into a second tank, and the second tank is configured to establish a substantially standing ultrasonic wave pattern of the ultrasonic waves inside the second tank; and the disposer is configured to dispose the textile sequentially into the first tank and the second tank. The disposer is configured to dispose the textile at a second distance from the second transducer into the second tank, wherein the second distance is determined based the second wavelength and the disposer is adapted to dispose multiple iterations of the textile through the second tank and each iteration of the textile is separated from adjacent iteration of the textile by a third distance, wherein the third distance is determined based on the second wavelength and the disposer disposes each of the iterations of the textile at locations that corresponds to locations of antinodes of the substantially standing ultrasonic wave pattern formed in the second tank. In a seventh embodiment, the second transducer and geometry of the second tank are configured to expose the textile to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2 and are adapted to transmit at least 8 watts/liter of ultrasonic power into the second tank.
According to another aspect the subject matter provides a method of manufacturing an apparatus comprising: providing a first tank; coupling a first transducer to the first tank, wherein the first transducer is configure to transmit ultrasonic waves of a first wavelength into the first tank and the first tank is configured to form a substantially standing ultrasound wave pattern into the first tank; and providing a disposer configured to dispose a textile at a first distance from the first transducer and into the first tank, wherein the first distance is determined based on the first wavelength. In one embodiment, the method includes configuring the first transducer and geometry of the first tank to cause the textile to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2 and transmit at least 8 watts/liter of ultrasonic power into the first tank. In a second embodiment the providing disposer includes providing a first plurality of rollers and adapting the first plurality of rollers to dispose multiple iterations of the textile through the first tank, wherein each of the iterations of the textile is separated from adjacent iteration of the textile by a distance determined based on the first wavelength. In third embodiment, the providing includes adapting the disposer to dispose each of the iterations of the textile at a location that corresponds to location of an anti-node of the substantially standing ultrasonic wave pattern formed in the first tank. In a fourth embodiment, the method comprises configuring the apparatus to operate on a sweep frequency of ultrasonic waves, the sweep frequency is a band of frequencies around a first frequency, wherein the first frequency corresponds to the first wavelength and the disposer is configured to dispose the first textile at the first distance, the first distance is determined based on the first frequency.
The subject matter shall now be described with reference to the accompanying figures, wherein:
It shall become clear to a person, after reading this specification, that the following discussion is intended only for illustration purpose and not to limit to the described embodiments, and that the subject matter may be practiced without departing from the spirit of the subject matter in other embodiments different than the embodiments discussed herein. The subject matter is being described, for the purpose of explanation only, with the help of an example of an apparatus for impregnation of fluid and de-size chemicals in yarn and textile. However it shall become abundantly clear to a person, after reading this specification, that the subject matter may be practiced in other fluid impregnation applications, for example in bleaching; mercerizing, dyeing, chemical treatment and washing processes. It is also to be understood that the terminology used throughout the preceding and forthcoming discussion is for the purpose of describing particular embodiments only, and is not intended to be limiting. It must be noted that as used herein, the singular forms “a”, “an”, and “the” include plural references unless the context clearly expressly dictates otherwise. It also to be understood that ultrasonic transducers of wavelength A are discussed only for the explanation. It shall become abundantly clear to a person skilled in the art, after reading this specification, that practical transducers produce ultrasonic waves in a wavelength range λ±Δλ, where Δλ is small wavelength range around wavelength λ and that the subject matter may be accordingly adapted for the wavelengths λ±Δλ without departing from the basic spirit of the disclosed solution. It shall become clear to a person that the text “size” or “bonding chemicals and size” referred in this description unless otherwise stated are used to refer to a layer of bonding chemicals and natural or synthetic starch applied on to yarn before weaving. It should further be understood that throughout following discussion, text “tank”, “transducer/s”, “disposer”, “wavelength” etc. are referred to a general embodiment of the subject matter and applies mutatis mutandis to each of the embodiments discussed herein and to other embodiments that may be achieved by practicing the subject matter.
To fulfill a basic industry need of consistent, low cost, environment friendly, reliable and repeatable process the subject matter provides a solution for impregnation of yarn/textile using ultrasonic technology. The subject matter focuses on geometry of equipment and distance between transducer and textile, location of transducers and providing effective environment to cause impregnation of a fluid into the textile. The subject matter provides the geometry of equipment to establish substantially standing ultrasonic waves and positioning of textile at a predetermined location based on a number of parameters such as, ultrasonic power per square centimeter on textile, ultrasonic power per liter of fluid and contact time of textile and fluid, effective use of reflected ultrasonic waves that form standing wave pattern. Further the subject matter provides solution for handling variety of textiles for example, cotton, wool, polyester and other yarns have different characteristics of absorbency and requirement for impregnation by providing electronically controlled disposing of textile in a tank and electronically controlling positioning of textile and characteristics of ultrasonic waves, such as, sweep characteristics.
The apparatus 100 is configured to impregnate the textile 131 with a fluid that is filled in the first tank 101. Generally, the apparatus 100 is employed for impregnating textile 131 with water and other chemicals, for example, de-size chemicals, bleaching chemicals etc. In some embodiments, the textile 131 is impregnated prior to wet processing of the textile 131. It shall become clear to a person in the art, after reading this specification that the apparatus illustrated in
Operation of the apparatus 100 may be understood as follows. As shown in
The construction of the apparatus 100 may be understood as follows. The apparatus 100 has the first tank 101. The first tank 101 comprises the first wall 103 and the second wall 105. The first wall 103 is provided with the first transducer 107. The first transducer 107 is coupled to the first wall 103 and the first transducer 107 is configured to generate ultrasonic waves of a first wavelength (λ1). Material of the first wall 103 and second wall 105 is selected such that they optimally reflect the ultrasonic waves in the first tank 101. Distance between the first wall 103 and the second wall 105 is such that the ultrasonic waves transmitted in the first tank 101 establish a substantially standing wave pattern. In
Alternatively, based on size of the first tank 101 characteristics of the first transducer 107, the first wavelength (λ1) may be determined. In one embodiment, the height of the first tank 101 and the distance between the first wall 103 and the second wall 105 may be determined based on and length of textile (131) that travels through the first tank (101) and the number of iterations that the textile 131 makes through the fluid of the first tank 101. In some embodiments, the length of the textile 131 in first tank 101 is determined based on textile web speed in continuous production operation and a duration of time for which the textile 131 and the ultrasonically active fluid is desired to remain in contact (also referred to as “contact time”). Further based on the contact time required for particular textile type, and production speed etc., length of textile 131 in block 100 can be calculated. For example, if T is the contact time and S is the speed of production than length L may be calculated as L=T×S. In the shown example the height of block 100 may be adjusted according to the length L or the width may be adjusted to accommodate number of iterations of the textile 131.
The disposer 109.1, 109.2 disposes the textile 131 in the first tank 101 in such a manner that ultrasonic waves produced by the first transducer 107 travels in substantially perpendicular direction of the textile 131. The textile 131 is disposed substantially longitudinally across the first tank 101. It shall become clear, after reading this specification that the distance between the first wall 103 and the second wall 105 of the first tank 101 is substantially close to a number which is equal to the first wavelength (λ1) multiplied by an integer (n). In one embodiment the integer (n) may depend on the number of iterations of the textile 131 through the first tank 101. For example, in
In some embodiments, the geometry of the first tank 101 is determined based on the first wavelength (λ1) and power of ultrasonic waves that need to be transmitted into the first tank 101. For example if the power needed to be transmitted is 8 Watts/liter, then based on the first wavelength (λ1) distance between the first wall 103 and the second wall 105 may be determined. Based on the distance between the first wall 103 and the second wall 105, the first wavelength (λ1) and characteristics of the first transducer 107 height of the first wall 103, and second wall 105 may be determined so that 8 Watts/liter of ultrasonic power is transmitted into the first tank 101. In one example, the vertical height of the first and second walls 103, 105 and first transducer 107 is selected based on the time for which the textile 131 is desired to be exposed to the ultrasonic waves, the fluid, the first wavelength (λ1), power/liter of ultrasonic waves transmitted by the first transducer 107 into the first tank 101 and power/cm2 of the ultrasonic waves that the textile 131 is desired to be exposed to. In some embodiments, quality and type of textile 131 may be used to determine the geometry of the first tank 101. The geometry of the first tank 101 may also be decided by the web width of the textile 131. The first tank 101 is provided with the inlet 127 and the outlet 129 for allowing entry and exit of the fluid respectively. In one example, the first transducer 107 may be of 25 KHz, 4000 Watt for a surface area of one iteration of textile 131 of 7200 cm square exposed to the first transducer 107. In this case, the effective Watts/cm2 is slightly higher than 0.5 Watts/cm2.
The operation and construction of the embodiment 300 may be understood as follows. The textile 131 is unwound from the un-winder 301 and is subjected to a 3-stage impregnation process through the blocks 305, 100 and 200. Once the textile 131 has been through the blocks 305, 100 and 200 the textile 131 is transported and wound on the winder 313. The textile 131 is pulled by the nip rolls 303 and 311. The nip rolls 303 and 311 may be coupled to prime movers such as electric motors (not shown).
The block 305 comprises the fluid tank 315 and the outlet 325. In one embodiment, the fluid tank 315 receives fluid from the block 100 that is the outlet 129 may be coupled to an input of the fluid tank 315. At block 305 the textile 131 gets wet. Wetting of textile may help in adapting the textile 131 to expose it to ultrasonic cavitation and forming nuclei at its surface. For example, subjecting the textile 305 may remove large bubbles that form on the surface of textile 131 when the textile is introduced into the fluid however, does not remove finer bubbles in the inter-yarn space that get forwarded to block 100 along with the textile 131. Further wetting may help in removing undesired hard size. A plurality of rollers may be disposed in block 305 to facilitate the textile 131 to pass through the fluid in a plurality of iterations.
Construction and operation of
The degassing tank 317 is coupled to the inlet 227 of the block 200 through the valve 309 which controls the rate of flow of the fluid to the block 200 and also to the subsequent blocks namely 100 and 305. In one example, fluid in each block 100, 305 and 200 flow below fluid level surface of tank of each block 100, 200 and 305 in each of the blocks 100, 200 and 305 to reduce possibility of trapping air by fluid while flowing and excess fluid flows from one block to another starting from block 200 to block 100 and then to block 305 and ultimately the fluid exits from the outlet 325.
According to one possibility, the block 100, 200 and 305 may be provided with one or more circulation pumps (not shown). In one possibility, the circulation pump may pump the fluid from the bottom of tank and feed it back into the tank. According to one aspect, the subject matter provides that the circulation pump of respective block 100, 200 and 305 is configured such that the pump discharges the fluid on top of respective tanks 315, 101, and 201 however, level at which the pump discharges the fluid is below the fluid level in respective tanks. In another example, circulating fluid from bottom to top in each block 100, 200 and 305 may provide uniform concentration of fluid. In some embodiments, the fluid discharge at the top of section is below fluid level surface at low flow rate to avoid possibility of air trapping in fluid while circulating the fluid within the first tank 101 or the second tank 201. It should be understood that one or more pumps may be provided for circulating fluid in a given tank. In one embodiment, the ultrasonic power may be effectively utilized by positioning the transducers 107 and 207 such that the ultrasonic waves emitted by the transducer 107 and 207 are in the natural direction of the flow of the fluid which is from block 200 to block 100 and so on, as shown the
In the illustrated embodiment 300, it may be seen that there is a single stage of impregnation 305 that operates without ultrasonic transducers and the other two stages namely blocks 100 and 200 employ ultrasonic transducers for impregnating the textile 131. In some embodiments, a drying operation between the nip roll 311 and winder 313 may be provided.
In one embodiment, the apparatus 300 is monitored and controlled using programmable logic controllers (PLC) at every stage to ensure consistency and reliability of processes. If there is a change in textile type and process conditions, the logic controllers are suitably programmed to adapt to the changes thereof. Use of PLC provides enhanced consistency and reliability of process. Further, PLC provides flexibility to adapt for changes in textile type and compensate for the changes in process conditions. In one embodiment, a Piezo electric sensor may be used to control the ultrasonic transducer power for automatic adaptation of process needs and textile type.
In one embodiment, an ultrasonic generator operates with a sweep frequency in a band near to main operating frequency of ultrasonic transducer. In general, a wavelength of ultrasonic wave inside a fluid may not remain constant due to changes in the industrial operating and environmental factors such as change in temperature or concentration of the fluid. Further, maintaining the distance of the textile 131 substantially precisely at a distance of integral multiples of λ1/2 in block 100 may not be practically feasible due to the elastic structure of the textile 131, movement of the textile 131 around the combinations of rollers 113 and 117; 117, 119 and 121; and 121, 123 and 125 may give rise to changes in the distance of the textile 131 from the first wall 103. These issues also arise in the other stages of impregnation such as in block 200. The subject matter overcomes these practical issues by providing ultrasonic generators and the ultrasonic transducers 107, 207 that are capable of altering the frequency/wavelength of their operation. That is to say, the adapting the apparatus of the subject matter to operate on a sweep frequency. Consequently the wavelength of operation in a fast and continuous manner to accommodate for the changes in the distance of the textile 131 from the transducers 107, 207 and other operating conditions e.g. temperature and concentration. In one embodiment, the frequency and wavelength are changed to accommodate a shift in the position of the textile 131. By providing a continuously sweeping frequency assist in improving reliability and repeatability of the impregnation process in changing operating conditions. The sweep frequency of the ultrasonic generators may be adapted to changes in the environmental conditions such as slight web movement, temperature changes and fluid concentration changes.
Furthermore, disposing the textile 131 according to the subject matter into the first tank 101 or the second tank 201 also accounts for the attenuation of the ultrasonic waves. The nature (flexibility and transparency for ultrasonic waves and textile having thickness much less than wavelength) of the textile 131 is such that it leaves the ultrasonic waves substantially unaltered and causes negligible amount of attenuation. This feature enables that a single transducer may be used for exposing the textile 131 to ultrasonic waves/filed for multiple time by deploying multiple iterations of the textile 131 through the first tank 101. This feature increases the contact time of the textile 131, fluid and ultrasonic filed. This reduces number of transducers and power requirement of the transducer, while improving the contact time and hence assisting the solution reach industrially and commercially acceptable standards. Disposing iterations of the textile 131 according to the subject matter ensure substantially uniform, reliable and increased textile contact time while optimizing number of transducers and size of the apparatus.
Generally, when an ultrasonic based impregnation is tested in laboratory, often it is tested on a piece of a textile, therefore, does not account for challenges relating to up scaling the model on industry scale. One of the challenges that up-scaling of process to industry scale throws is power requirements of industry scale set up, wherein power is required by the industry scale set up is many times the power required by the lab set up and up scaling of the power requirement becomes prohibitively high. According to another problem faced while up scaling the laboratory set up to industry set up is introducing rollers for continuous feeding of textile. Because, introducing rollers result in increased in size of the set up and therefore, also require increase size, power and number of ultrasonic transducers which is not practical for industry because power requirement of the transducers is prohibitively high for the industry. Furthermore using smaller size of rollers is not desirable as smaller size of roller cause wrinkle issue with the textile. The size of the rollers is about 100 mm to 200 mm which may generally an industry standard. The subject matter addresses the above challenge by effectively introducing the rollers, while disposing the textile 131 at a distance from the source of the ultrasonic as taught with reference to
Based on flow rate of fluid in block 200 from dosing pump, the wetting agent and other chemicals may added at block 200. According one aspect of the subject matter, amount of wetting agent and other chemical required for processing textile according to the subject matter may be considerably lower as compared with conventional methods. In some embodiments, the subject matter may demonstrate reduction in the quantity of wetting agent up to one fifth or up to one fourth of the normal usage in industry. Water flow rate to block 200 from degas tank may be regulated with valve 309 based on textile Kg/Hour rate.
Diffusion is phenomenon, which occurs in textile, without regards to the volume of the fluid. Further, ultrasonic power required is higher for higher volume of the fluid is used. Therefore, it is desirable to keep the volume of the fluid at its lowest as smaller volume while leave the diffusion unaffected it assist in conserving power of the ultrasonic transducer. While it is desirable that the volume of the fluid is kept at its minimum, however reduction in volume of the fluid must accompany with increase in the velocity of fluid through the tank in order to keep up effective concentration of fluids. However, increased velocity of fluid through the tank diminishes ultrasonic effect. That is beyond certain point further reducing the volume of the fluid in the tanks become counterproductive because the fluid velocity required starts disrupting the effect of ultrasonic on the textile. Providing the size of the tank in the order of the wavelength and disposing the textile according to the subject matter addresses this conflict between the velocity of fluid, volume of fluid and ultrasonic power and provides an effective solution for impregnation of textile.
It shall become clear to a person, after reading this specification, majority of ultrasonic effect on textile is with ultrasonic cavitation and micro jets generated with cavitation collapse, apart from pressure wave and acoustic streaming. A saturated layer of fluid is formed near to the textile surface, which prevents fresh fluid to impregnate to equalize fluid concentration within textile and fluid concentration in tank. Ultrasonic cavitation phenomenon breaks this saturated fluid layer near to textile forming a diffusion boundary layer, thus enabling better diffusion for impregnation and also equalization of localized of fluid concentration near to textile. Disposing textile at a distance that is in multiple of λ/2 is advantageous because, cavitation phenomena are highest at such distances, to which the textile 131 is exposed. Formation and collapsing of cavitation bubbles in close vicinity of the textile 131 or within inter-yarn pores of textile 131 further enhances the impregnation as it creates micro-jets and micro-streaming which shoots fluids in the intra-yarn and inter-yarn space of the textile 131. The solution given in the subject matter achieves higher contact time of textile with ultrasonically active fluid for continuously moving textile 131. The same discussion also applied to blocks 100, 200 mutatis mutandis.
Working of the subject matter according to an embodiment may be understood with the help of illustrative
The transducer 503 is coupled to the proximal wall 505. In some embodiments, the distance between transducer 503 and the proximal wall 505 is negligible. In some embodiments, when there is a non-negligible distant between the transducer 503 and the proximal wall 505, the standing wave pattern and the dimensions/configuration of the apparatus is determined by the distance between the transducer 503, the proximal wall 505 and the distant wall 501. The proximal wall 505 is selected of a material that can pass the ultrasonic waves from one side with least attenuation in one direction, whereas reflects the waves substantially totally from other side. In some embodiments, the proximal wall 505 is an ultrasonic source. The standing ultrasonic wave pattern is formed between the proximal wall 505 and distal wall 501. Standing wave pattern of ultrasonic generates highest cavitation phenomenon at positions, which are at a distance that is integer multiples of λ/2. The distance is determined from the proximal wall 505 or the transducer 503. Hence the textiles 502, 507, 509, 511 and/or 519 are separated at a distance in multiples of λ/2 from the transducer 503 as shown in the
The standing wave pattern creates pressure antinodes at (n×λ/2) and pressure node at (2n+1)λ/4. (Where “n” is an integer). This way effective ultrasonic pressure at multiple of λ/2 distances will be almost twice, giving rise to cavitations at regions where textile 502, 507, 509, 511 and/or 519 are disposed. Further, ultrasonic pressure difference between pressure antinodes at nλ/2 and pressure nodes at (2n+1)λ/4 helps in uniform distribution of fluid concentration with low velocity micro-flow. Geometrical placement of yarn/fabric/textile is guided so that yarn/fabric/textile remains at place of pressure antinodes which are higher cavitation zones.
The textile 502, 507, 509, 511 and/or 519 impregnated according to the subject matter provides a number of advantages as discussed earlier. The above processes are generally governed by physical processes of fluid exchange between textile by convection and diffusion. Generally, impregnation of fluid in-between yarn (inter-yarn) portion of textile results from convection, which is comparatively faster physical process than diffusion. However, impregnation of fluid within yarn (intra-yarn) which is major part of total impregnation and it results from diffusion. That is, the main process of impregnation involves diffusion. The diffusion depends on yarn surface characteristics and is generally difficult to enhance. The subject matter provides solution to this problem by effectively employing the ultrasonic for enhancing both the physical processes of impregnation to textile, convection and diffusion.
The subject matter provides a number of flexibilities in processing the textile, for example, the amount of absorption of fluid by the textile may be improved without making extensive changes in the system. Generally, existing solutions require repeating the wetting processes or running the textile multiple times through fluid. Current industrial processes are based on method of concentration exchange between the textile and fluid by moving textile multiple times through the fluid. The subject matter provides improvement over these processes. The existing methods not only fail to provide desired results but also, hamper production, waste fluids, water wastage is high, power consuming, result in higher chemical usage and environmentally hazardous effluents, resource intensive in terms of size of equipment, cost of running, infrastructure etc, higher temperatures of process, and higher textile contact time with fluid for increasing impregnation. Therefore, these methods are undesirable.
Further, there are attempts to enhance diffusion process by increasing flow through textile by high speed fluid jets or higher temperature treatment. However, high speed fluid jets fail to provide uniform impregnation especially when the textile itself is not uniformly weaved and high temperatures tend to damage the textile and are slow process. The subject matter removes requirement of high speed fluid jets or high temperature and provides substantially uniform impregnation.
The subject matter further addresses challenges related to developing an industry scale application of ultrasonic based impregnation of textile. Industry application of ultrasonic based textile impregnation is challenging because the ultrasonic pressure wave may cause the textile to move. Such characteristic of textile, calls for power requirement of ultrasonic in terms of Watts/cm2 instead of normal standard cleaning calculation in Watts/liter. Further, industrial web width and roller size is generally higher than 1800 mm and 100 mm respectively. Therefore, for industry applications up-scaling of ultrasound impregnation apparatus results in ultrasonic power requirements prohibitively higher than what is practical. The subject matter solves this problem by optimally adjusting and selecting geometry of the tank and the transducers, and iterations of textile into the tank, to exploit cavitations caused by the ultrasonic waves such that ultrasonic power required in an unit area of textile (Watts/cm2) for a given contact time is achieved without compromising on the ultrasonic power required in the tank for a give unit of fluid (Watts/liter). Further, the subject matter provide degassing and flow control and direction of flow of fluid which improves effectiveness of ultrasonic based impregnation, as non-degassed fluid generally adversely affect the ultrasonic impregnation. The subject matter also provides flexibility of construction of the apparatus because, the ultrasonic waves operation on the textile is substantially independent of gravity, the tank and transducers may be deployed horizontally or vertically or at any suitable angle, with appropriate adjustments without effecting efficiency of the apparatus.
While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject matter, some features may be omitted. In some other cases, some features may be emphasized while others are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternatively, the methods may be performed in manner or order different than what is explained without departing from the spirit of the subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter covers all modifications, equivalents, and alternatives within the spirit and scope of the subject matter as described above.
In the above description, while describing the subject matter, some of the proprietary terms as well as some proprietary terms of expression including trademarks or other copyrighted subject matter may have been used, the applicant has taken best care in acknowledge the ownership of the proprietary subject matter. However, if the applicant has inadvertently omitted any such acknowledgement, the applicant states that any such omission is unintentional and without any malicious intention and the applicant states that should any such inadvertent omission is brought to the attention of the applicant, the applicant is willing take actions that the applicant believes are fit to acknowledge such proprietary ownership.
Patent documents relating to the numbers EP 0 969 131 A1, U.S. Pat. No. 3,688,527, and WO99/37844 show some solutions. While these documents attempt to reach at some solution that employ ultrasound in cleaning, these documents suffer from a number of limitations, including those discussed previously relating to laboratory scale experiments and non-viability on commercial scale and other technical challenges.
Specifically EP 0 969 131 A1 discloses a device for treating textile, comprising a tank (2) for holding treatment liquid (3), conveyor means (4) for conveying a textile substrate (7) which is to be treated through the tank (2), a transducer (8) for generating ultrasonic vibrations in the treatment liquid (3), an interference element (19) placed opposite the transducer for together delimiting a vibration cavity (13), wherein the transducer (8) together with the interference element (19) is designed to generate an interference pattern in the vibration cavity (13) of ultrasonic vibrations amplifying each other, in which a concentration area (11) of intensified vibration energy occurs at a distance from the transducer (8) and the interference element (19), in which the conveyor means (4) are designed to guide the textile substrate (7) through the concentration area (11), and in which energy of the ultrasonic vibrations is destined to dissipate by means of cavitation in the concentration area (11) at the location of the textile substrate (7).
While EP 0 969 131 A1 attempts to employ ultrasonic wave solution in textile industry, it fails to recognizes challenges relating to obtaining a stable concentration area (11), in which energy of the ultrasonic vibrations is destined to dissipate by means of cavitation. Because the concentration area (11) is highly susceptible to physical parameters of the medium. The position of concentration area (11) changes with temperature pressure etc. In fact in some case, concentration area (11) may not be in a substantially vertically aligned, as envisioned by the EP 0 969 131 A1, due to changes in temperature of the medium at different heights in a given tank. Furthermore, EP 0 969 131 A1 provides a complex solution which employs a number of transducers each focusing in different direction, interfering elements and ultrasound unit 9. The present subject matter solves at least both the problems associated with the EP 0 969 131 A1. The present subject matter configures the walls of the tank itself eliminating need of a separate ultrasonic unit 9 altogether. Further the apparatus of the present subject matter operates on a sweep frequency. These features enable the apparatus to ensure that the textile remains in the cavitation zone, either by adjustment of the rollers that dispose the textile into the tank, or by disposing the textile diagonally/obliquely (as shown in
In addition, the ultrasound unit 9 of EP 0 969 131 A1 requires multiple combinations of transducers and interference elements (the interference element being transducers themselves) and some focusing arrangement to guide the ultrasonic waves in specific direction, into the tank. This arrangement of the EP 0 969 131 A1 not only makes the solution of the EP 0 969 131 A1 practically not workable but also makes it more complex. This is because, when a number of transducers each of them focusing in different directions (see, FIG. 1 items 8 of EP 0 969 131 A1) pass a number of ultrasonic waves through a single continuous medium, the medium does not see these waves as separate waves coming from different sources/direction. Instead the medium sees some convolution of waves. More so, no transducer is an ideal transducer which would produce exact same frequency each time. Further the physical parameters of the medium may also alter the frequency of the ultrasound. Practically achieving a standing wave pattern from this convolution of waves is if not impossible then certainly difficult and may be a matter of chance. For the same reason cavitation zone may shift based on a resultant frequency that the medium observes and physical parameters (temperature etc) of the medium. Therefore obtaining a commercially viable solution using EP 0 969 131 A1 is practically impossible.
These and other challenges are solved by the present subject matter. The present subject matter could solve these problems because, the present subject matter exploits a number of technical features, e.g. configuring the apparatus to operate on sweep frequency. This feature has been elaborated in paragraph [0033] of the specification in detail with reference to
As explained in paragraphs [0023] and [0033] of the specification, the apparatus may be configured to operate based on the sweep frequency and dispose textile using the rollers accordingly in number of ways. It shall become clear to a person in the art that the textile may be kept in the cavitation zone by a number of ways, which may include combination of adjustment of rollers and adjustment of frequency etc. In one embodiment, the apparatus may be configured to solve these problems by disposing the textile in a diagonal/oblique manner (shown in
Furthermore, the EP 0 969 131 A1 also fails commercial viability test because of only single iteration of textile may be treated at a given time, whereas the subject matter efficiently utilizes energy and time by enabling disposing of textile in multiple iterations without compromising on the advantages of cavitation zones and therefore the subject matter provides a better and cheaper solution.
Similarly, U.S. Pat. No. 3,688,527 discloses, a method and apparatus for cleaning mechanically bonded contaminants from a resilient web in a fluid medium. Here U.S. Pat. No. 3,688,527 diverts from the present subject matter, more often than not the textile is rather delicate and not resilient. It is therefore U.S. Pat. No. 3,688,527 shows a sonotrode type of transducer, generally used for cutting and welding operations. Employing U.S. Pat. No. 3,688,527 in textile industry would only result in damaged textile. It is therefore despite of U.S. Pat. No. 3,688,527 being in public since 1972, industrial scale solution employing ultrasounds to process textile are not available in the market.
WO99/37844 is another document, the document does not discuss either the problems addressed by the present subject matter or provides a solution thereof. Furthermore, for treating different sides of the textile, the WO99/37844 requires two transducers one for each side of the textile. It does not provide any indication or motivation for disposing the textile based on either sweep frequency or corresponding wavelength.
It may also be noticed that even a combination of the aforementioned documents would not result in the solution of the present subject matter because none of the cited documents teach, suggest or provide any motivation, alone or in combination, to reach at the subject matter. Emphasis is supplied to the fact that none of the above documents configure the first tank itself by arranging first wall and the second wall of the first tank in manner that substantially standing wave pattern is formed in the first tank. Thereby, the present subject matter eliminates requirement of any separate ultrasound unit 9 of EP 0 969 131 A1 and item 34 of U.S. Pat. No. 3,688,527 respectively require. While WO99/37844 altogether fails to discuss any such feature of obtaining substantially standing wave pattern. This feature, alone, of the present subject matter not only reduces the complexity of design but also makes the present subject matter commercially more advantageous.
At least for the above reasons the present subject matter is not only superior but also desirable as compared with any of the EP 0 969 131 A1, U.S. Pat. No. 3,688,527 and WO99/37844 or a combination thereof. In fact, it appears that because of the above discussed technical and commercial difficulties with the EP 969 131 A1 and WO99/37844, these documents were not perused till the logical end of the application.
The present subject matter provides an apparatus comprising: a first transducer (107), characterized in that wherein the first transducer (107) is adapted to transmit ultrasonic waves of a first wavelength into a first tank (101), and characterized in that the first tank (101) is configured to establish a substantially standing ultrasonic wave pattern of the ultrasonic waves inside the first tank (101); and a disposer (109.1 and 109.2) adapted to dispose a textile (131) into the first tank (101) at a first distance from the first transducer (107), wherein the first distance is determined based the first wavelength and, wherein the first tank (101) comprises a first wall (103) and a second wall (105), the first transducer (107) is coupled to the first wall (103) and the second wall (105) is configured to reflect the ultrasonic waves and the first wall (103) and the second (105) are separated from each other to establish the substantially standing wave pattern into the first tank (101) resulting in multiple cavitation zones and wherein the apparatus is configured to operate on a sweep frequency of ultrasonic waves, the sweep frequency is a band of frequencies around a first frequency, wherein the first frequency corresponds to the first wavelength and the disposer (109.1 and 109.2) is configured to dispose the textile (131) at the first distance, the first distance is determined based on the first frequency. In one embodiment, the first transducer (107) and geometry of the first tank (101) are configured to expose the textile (131) to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2. In a second embodiment, the first transducer (107) and geometry of the first tank (101) are adapted to transmit at least 8 watts/liter of ultrasonic power into the first tank (101). In a third embodiment, the disposer (109.1 and 109.2) comprises a first plurality of rollers (111, 117, 119, 125, 113, 115,121 and 123) and the first plurality of rollers (111, 117, 119, 125, 113, 115, 121 and 123) are adapted to dispose multiple iterations of the textile (131) through the first tank (101) and each iteration of the textile (131) is separated from adjacent iteration of the textile (131) by a distance, wherein the distance is determined based on the first wavelength. In a fourth embodiment, the disposer (109.1 and 109.2) disposes each of the iterations of the textile (131) at locations that corresponds to locations of antinodes of the substantially standing ultrasonic wave pattern formed in the first tank (101). In a fifth embodiment, the apparatus comprises a second transducer (207), wherein the second transducer (207) is adapted to transmit ultrasonic waves of a second wavelength into a second tank (201), and the second tank (201) is configured to establish a substantially standing ultrasonic wave pattern of the ultrasonic waves inside the second tank (201); and the disposer (109.1 and 109.2) is configured to dispose the textile (131) sequentially into the first tank (101) and the second tank (201). In a sixth embodiment, the disposer (109.1 and 109.2) is configured to dispose the textile (131) at a second distance from the second transducer (207) into the second tank (201), wherein the second distance is determined based the second wavelength and the disposer (109.1 and 109.2) is adapted to dispose multiple iterations of the textile (131) through the second tank (201) and each iteration of the textile (131) is separated from adjacent iteration of the textile (131) by a third distance, wherein the third distance is determined based on the second wavelength and the disposer (109.1 and 109.2) disposes each of the iterations of the textile (131) at locations that corresponds to locations of antinodes of the substantially standing ultrasonic wave pattern formed in the second tank (201). In a seventh embodiment, the second transducer (207) and geometry of the second tank (201) are configured to expose the textile (131) to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2 and are adapted to transmit at least 8 watts/liter of ultrasonic power into the second tank (201).
According to another aspect, the present subject matter provides a method of manufacturing an apparatus comprising: providing a first tank (101) wherein the first tank (101) comprises a first wall (103) and a second wall (105); characterized in that coupling a first transducer (107) to the first wall (103) of the first tank (101), wherein the first transducer (107) is configure to transmit ultrasonic waves of a first wavelength into the first tank (101); configuring the second wall (105) to reflect the ultrasonic waves and the first wall (103) and the second (105) are separated from each other to establish the substantially standing wave pattern into the first tank (101) resulting in multiple cavitation zones; providing a disposer (109.1 and 109.2) configured to dispose a textile (131) at a first distance from the first transducer (107) and into the first tank (101), wherein the first distance is determined based on the first wavelength; and configuring the apparatus to operate on a sweep frequency of ultrasonic waves, the sweep frequency is a band of frequencies around a first frequency, wherein the first frequency corresponds to the first wavelength and the disposer (109.1 and 109.2) is configured to dispose the textile (131) at the first distance, the first distance is determined based on the first frequency. In a first embodiment, the method includes configuring the first transducer (107) and geometry of the first tank (101) to: expose the textile (131) to ultrasonic power in a range between 0.2 Watts/cm2 and 2 Watts/cm2; and transmit at least 8 watts/liter of ultrasonic power into the first tank (101). In a second embodiment, providing the disposer (109.1 and 109.2) includes providing a first plurality of rollers (111, 117, 119, 125, 113, 115, 121 and 123) and adapting the first plurality of rollers (111, 117, 119, 125, 113, 115, 121 and 123) to dispose multiple iterations of the textile (131) through the first tank (101), wherein each iteration of the textile (131) is separated from adjacent iteration of the textile (131) by a distance determined based on the first wavelength. In a third embodiment, providing includes adapting the disposer (109.1 and 109.2) to dispose each of the iterations of the textile (131) at a location that corresponds to location of an antinode of the substantially standing ultrasonic wave pattern formed in the first tank (101).
| Number | Date | Country | Kind |
|---|---|---|---|
| 3002/MUM/2015 | Aug 2015 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2016/054693 | 8/3/2016 | WO | 00 |
