This application takes priority from and claims the benefit of Turkish Patent Application 2020/22396 filed on Dec. 30, 2020, the contents of which are herein incorporated by reference.
The invention relates to an Ultrasonic drying method developed for drying washed and dyed yarns with the Ultrasonic sound waves in the process of dyeing one or more yarns at a desired length in one or more colors during the manufacture of products such as carpet, hand-knit, knitwear in the textile sector, and an ultrasonic drying system using this method.
Textile is classified into three main branches including yarn weaving, fabric weaving and finishing, and each of them form a separate sector in itself. After spinning the fibers as a yarn, the process of dyeing before they become woven or knit fabrics is called yarn dyeing. Yarn dyeing is less costly compared to fibre or tops (rib) dyeing. Yarn dyeing can be performed in two different yarn forms. Firstly, the yarns are wound as a bobbin and dyed in this form, secondly the yarns are dyed in the form of a skein. Generally the first method of dyeing of the yarn wound onto the bobbin is preferred. In this application, the yarns are wound on pressurized cones or bushings made of metal or plastic. These cylindrical bobbins are uniform in diameter, such that they ensure a more even dyeing process.
After the dyeing process being applied today, the excess dye pigments on the yarns, which are not absorbed need to be washed away. This process directly affects the production quality. When the yarns sooked upon washing, they need to be dried and brought into a certain humidity level before they become a final product. At the same time, the maximum and minimum humidity values in the yarns are defined by the standards, and these values should not be exceeded. If the yarns are not within the standard humidity values before the final product is obtained, they are accepted as a defective product. Thus, the drying process after washing is essential. Drying process directly affects the quality, production rate and manufacturing cost.
In the currently applied methods, the yarns to be dried are firstly passed over an air vacuum unit, and water is tried to be removed therefrom as much as possible. Then, these yarns are passed through a hot air tunnel and the remaining water thereon is evaporated and removed. Especially quite long drying tunnels are used for drying yarns of a type with high water absorption, such as viscose, via this method. These drying tunnels have been developed to evaporate the water on the yarn to be dried by blowing the heated air on the yarns with the aid of a fan. The reason for an excessive energy consumption to heat the aforementioned drying tunnels is the use of longer tunnels for the removal of water and drying process especially in yarns with high water absorption. Consequently, the energy needed in this context is quite high, and this directly affects the manufacturing costs in a negative way. On the other hand, a certain period of time is required to evaporate the water on the yarn by heating. As the amount of water increases, the production rate decreases since the evaporation and removal of water by heating takes a long time. Thus, this method used determines the production rate. For these reasons, an effective drying means much more production.
While increasing the efficiency of dyeing process in yarn manufacturing, many studies have been carried out and new systems/methods have been developed, in order to reduce the manufacturing costs and rate of waste. One of these studies is the invention regarding the patent application no. CN106192270 (A) and titled “A single yarn dyeing method and system”. The invention relates to a single yarn dyeing method which includes the process steps of pretreating the yarn from a yarn cylinder for washing under an Ultrasonic wave condition; dyeing the yarn under an Ultrasonic wave condition after the removal of impurity; after dyeing, applying a process of color fixation to the yarn; after the color fixation process, drying the yarn, provided that the temperature is from 80 to 100° C.; after drying, determining the tension of the yarn and ultimately winding on a roll. The invention also provides a single yarn dyeing system corresponding to a single yarn dyeing method. According to a single yarn dyeing method provided by the invention, as the yarn is fed directly into a drying machine for drying after pretreatment, dyeing and color fixation, the cylinder releasing and dehydrating stages are saved, and all working procedures in the preparation process starting from a primary colored yarn to the dyed final product are continuously performed without any delay in the operation, compared to a present yarn dyeing method. The efficiency of a single yarn dyeing process is improved and the energy conservation is provided, by means of the invention.
Another study is the invention regarding the patent application no. TR 2019/14609 and titled “A method developed for the production of colored denim fabric after dyeing the warp yarns in various colors in an indigo warp dyeing machine”. The invention relates to a method developed for the production of a colored denim fabric by dyeing the warp yarns in various colors in an indigo warp dyeing machine usable in warp yarn dyeing process in the textile sector, characterized in that it includes a creel portion onto which the warp yarns are wound; a pretreatment portion, which comprises a first vessel, a second vessel and a third vessel, into which the warp yarns exiting from the creel portion are introduced; a dyeing portion, which includes a fourth vessel, a fifth vessel, a sixth vessel, a seventh vessel, an eighth vessel, a ninth vessel, a tenth vessel, an eleventh vessel, a twelfth vessel and a thirteenth vessel following the pretreatment portion; a washing portion, a third drying cylinders where the warp yarns exiting from the washing portion are dried, a sizing portion in which the warp yarns exiting from the third drying cylinder are sized, a fourth drying cylinders in which the sized warp yarns are dried, an accumulator portion to which the dried warp yarns are introduced, a beam winding portion onto which the warp yarns exiting from the accumulator portion are wound, as well as the process steps for drying the warp yarns exiting from the creel portion in the first drying cylinder after they washed in the pre-treatment portion, dyeing the dried warp yarns in the fourteenth vessel cold and dry at 250-300 degrees without passing (bypassing) the fourth vessel, the fifth vessel, the sixth vessel, the seventh vessel, the eighth vessel, the ninth vessel, the tenth vessel, the eleventh vessel, the twelfth vessel and the thirteenth vessel situated in the dyeing portion, and drying the warp yarns exiting from the fourteenth vessel in the second drying cylinders.
As the current studies generally focus on improving dyeing efficiency, they have no effect on solving the problems arising in the drying stage. Consequently, the need for eliminating the disadvantages present in the state of art and an efficient drying of the dyed and washed yarns and the incapability of present solutions made it essential to realize a development in the related technical field.
The present invention relates to an Ultrasonic drying method developed for drying the washed and dyed yarns with the Ultrasonic sound waves in the process of dyeing one or more yarns at a desired length in one or more colors in the manufacture of products such as carpet, hand-knit, knitwear in the textile sector, and an ultrasonic drying system using this method, which fulfil the aforementioned needs, eliminate all the disadvantages and provide some additional advantages.
In the light of the state of the art, an object of the invention is to allow the undesired water on the yarns to be almost completely removed by performing the drying process using an Ultrasonic vibration is.
The object of the invention is to allow the yarns to have the desired humidity level through a shorter hot air tunnel by almost completely removing the undesired water on the yarn via an Ultrasonic drying system.
Another object of the invention is to shorten the processing time and to reduce the energy consumption by allowing the yarn to have the desired humidity level using a shorter air drying tunnel.
Another object of the invention is to reduce the cost and increase the production by allowing the use of a 80% shorter hot air drying tunnel than the present systems by means of an Ultrasonic drying system.
The structural and characteristic properties of the invention and all advantages thereof will be understood more clearly on the basis of the figures given below and the detailed explanation given by reference to these figures, therefore, the evaluation should be made by considering these figures and the detailed explanations thereof.
In order to clearly understand the embodiment of the present invention and the advantages thereof together with the additional elements, it should be evaluated with the figures described below.
In this detailed description, an Ultrasonic drying method developed for drying the washed and dyed wet yarns (300) with the Ultrasonic sound waves in the process of dyeing one or more yarns at a desired length in one or more colors in the manufacture of products such as carpet, hand-knit, knitwear in the textile sector, and an ultrasonic drying system (100) using this method are described merely as an example in a non-limiting way for better understanding of the subject.
The Ultrasonic drying system (100) of the invention in which the water on the wet yarn (300) is removed via a vibration effect of high sound waves is an is used in the yarn dyeing and drying machines (200) which consist of a creel (201) to which the bobbins of the yarns is firstly attached for processing, a drawing godet (202) which draws the yarns from the creel (201) a preevaporation unit (203) which prepares the yarns for dyeing, a dyeing unit (204) which dyes the yarns in the desired color or pattern, a spreader (205) which spreads the yarns on the conveying belt in a ring form, a frieze unit (206) which transfers the yarns into the conveying belt after being crimped, a fixing boiler (207) (heat treating boiler) in which the yarns are subjected to a fixing process, a washing unit (208) in which the yarns are washed, a vacuum unit (209) in which the excess water of the yarns is removed, a drying tunnel (210) in which the humidity of the yarns are removed via hot air, a cooling unit (211) in which the yarns are cooled via a fan, an accumulator (212) where yarns are stored for later processing, and a bobbin winder (213) on which the yarns are rewound as a bobbin. Briefly, in the yarn dyeing and drying machines (200) shown in
In the aforementioned yarn dyeing and drying machine (200), the yarns in the form of bobbins attached to the creel (201) are drawn in a regular tension from the preevaporation unit (203) and dyeing unit (204) by the drafting godet (202). After the dyeing process, the yarns are spread by the spreader (205), or if the frieze (crimping) yarn is to be produced, the yarns are spread on the conveying belt by the frieze unit (206) (crimping) instead of the spreader (205). The yarns spread on the conveying belt are introduced to the washing unit (208) by passing through the fixing boiler (207) for the heat treatment. After the dyeing process, the washing process is performed in the washing unit (208) by water or a diluted cleaning agent in order to remove the undesired dyeing pigments or dyeing residual on the yarns. This washing process is realized by pressure injection, or by directly pouring the cleaning fluid thereon. After this process, the wet yarns (300) should be subjected to a drying process to maintain the production process and obtain the required humidity standards for the yarn production. The first step of this process is the absorption/vacuuming of the excess water on the wet yarns (300) as much as possible via a vacuum unit (209). Since the vacuuming method is insufficient to obtain the desired dryness depending on the desired production rate, a hot air drying tunnel (210) is used to decrease the humidity level of the yarns to an optimal extent. The Ultrasonic drying system (100) of the invention removes the water particles (500) present on the wet yarns (300) before the drying tunnel (210), while providing a more efficient drying operation in the shorter drying tunnels (210).
The Ultrasonic drying system (100) shown in
In the Ultrasonic drying method of the invention, the wet yarns (300) from the washing unit (208) are subjected to the vibration acquired by the high sound waves in the Ultrasonic system (100), and are dried by removing the water thereon by approximately 90% to 99%. The horn (103) to which the Ultrasonic booster (101) positioned in the Ultrasonic drying system (100) is connected and an adjustable control panel (102) (generator drive) thereof are used. In the Ultrasonic drying method the wet yarns (300) are passed through the Ultrasonic drying system (100) at a determined tautness via inlet idler roller (104) and outlet idler roller (105). The Ultrasonic sound waves generated by the Ultrasonic booster (101 are transmitted onto the wet yarn (300) bundle by the horn (103). The frequency of this sound wave is set by the control panel (102) on the basis of the yarn property. The water contained in the wet yarns (300) is removed by these sound waves in the form of water particles (500). The substantially dehydrated yarns (400) are transmitted to the drying tunnel (210) from the Ultrasonic drying system (100). This process is carried out with a continuous yarn flow.
Number | Date | Country | Kind |
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2020/22396 | Dec 2020 | TR | national |