Ultrasonic Yarn Drying System

Abstract

An ultrasonic drying method used in yarn dyeing and drying machine (200) for drying the washed and dyed wet yarns (300) 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 to an ultrasonic drying system (100) for performing this method, wherein the system contains an Ultrasonic booster (101) which creates sound waves to be transmitted over the wet yarn (300) bundle the excess water of which has been removed by the vacuum unit (209) to remove the water therein before the drying tunnel (210); a horn (103) which is positioned between the ultrasonic booster (101) and the wet yarn (300) to transfer the sound waves generated by the Ultrasonic booster (101) to the wet yarn (300) bundle.

Claims

1. An Ultrasonic drying method used in the yarn dyeing and drying machine (200) for drying the washed and dyed wet yarns (300) 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) for performing this method characterized by comprising; an Ultrasonic booster (101) which creates sound waves to be transmitted onto the wet yarn (300) bundle, the excess water of which has been removed by the vacuum unit (209) to remove the water contained therein before the drying tunnel (210); a horn (103) which is positioned between the Ultrasonic booster (101) and the wet yarn (300) to transfer the sound waves generated by the ultrasonic booster (101) to the wet yarn (300) bundle.

2. The Ultrasonic drying system (100) according to claim 1, characterized in that it is positioned between the vacuum unit (209) and the drying tunnel (210).

3. The Ultrasonic drying system (100) according to claim 1, characterized in that it includes a control panel (102) to which the Ultrasonic booster (101) is connected in order to set the frequency of the sound waves to be transmitted.

4. The Ultrasonic drying system (100) according to claim 1, characterized in that it includes an inlet idler cylinder (104) which cooperates with the outlet idler cylinder (105) to keep the yarn bundle stretched and is positioned in the section where the wet yarns (300) are introduced to the Ultrasonic drying system (100).

5. The Ultrasonic drying system (100) according to claim 1, characterized in that it includes an outlet idler cylinder (105), which cooperates with the inlet idler cylinder (104) to keep the yarn bundle stretched and is positioned in the section where the dehydrated yarns (400) exit from the Ultrasonic drying system (100).

6. The Ultrasonic drying method for drying the washed and dyed wet yarns (300) 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 characterized in that it includes a process step of subjecting the wet yarns (300) from the washing unit (208) to the vibration acquired by the high sound waves generated by the Ultrasonic booster (101) to remove the excess water thereon.

7. The Ultrasonic drying method according to claim 6, characterized in that it includes a process step of transferring the Ultrasonic sound waves generated by the Ultrasonic booster (101) on the wet yarn (300) bundle by the horn (103).

8. The Ultrasonic drying method according to claim 6, characterized in that it includes a process step of setting the frequency of the sound wave to be generated by the Ultrasonic booster (101) via the control panel (102) with regard to the yarn property.

9. The Ultrasonic drying method according to claim 6, characterized in that it includes a process step of passing the wet yarns (300) through the Ultrasonic drying system (100) at a determined stretch via the inlet idler cylinder (104) and the outlet idler cylinder (105).

10. The Ultrasonic drying method according to claim 6, characterized in that it includes a process step of transferring the dehydrated yarns (400) exiting from the Ultrasonic drying system (100) to the drying tunnel (210).

Description

BRIEF DESCRIPTION OF DRAWINGS

[0015] 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.

[0016] FIG. 1 is a schematic overall view of a yarn dyeing and drying machine; and

[0017] FIG. 2 is a schematic overall view of an Ultrasonic drying system.

REFERENCE LIST

[0018] 100. Ultrasonic drying system [0019] 101. Ultrasonic Booster [0020] 102. Control panel [0021] 103. Horn [0022] 104. Inlet idler cylinder [0023] 105. Outlet idler cylinder [0024] 200. Yarn dyeing and drying machine [0025] 201. Creel [0026] 202. Drawing godet [0027] 203. Preevaporation [0028] 204. Dyeing unit [0029] 205. Spreader [0030] 206. Frieze unit [0031] 207. Fixing boiler [0032] 208. Washing unit [0033] 209. Vacuum unit [0034] 210. Drying tunnel [0035] 211. Cooling unit [0036] 212. Accumulator [0037] 213. Bobbin winder [0038] 300. Wet yarn [0039] 400. Dehydrated yarn [0040] 500. Water particles

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

[0041] 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.

[0042] 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 FIG. 1, the yarns are respectively drawn from the creel (201) by the drawing godet (202), and they are spread on the conveying belt by the spreader (205) and the frieze unit (206) after the yarns transferred to the dyeing unit (204) through the preevaporation unit (203) are dyed. Afterwards these yarns are introduced to the washing unit (208) by passing through the fixing boiler (207) on the conveying belt and are washed and subjected to a vacuuming process, respectively. The wet yarns (300) the excess water of which is removed via the vacuum unit (209) are passed through the Ultrasonic drying system (100), and the undesired water thereon is almost completely removed by means of a shaking effect of a high frequency Ultrasonic vibration. The dehydrated yarns (400) exiting from the Ultrasonic drying system (100) are passed through the drying tunnel (210). Since the water on the wet yarn (300) is almost completely removed by the Ultrasonic vibration, a 80% shorter drying tunnel (210) than the present applications may be used to provide the desired humidity level in the final product. Although this drying tunnel (210) length is shorter compared to those used in the present methods, much more effective drying process is obtained. So it is possible to provide more production by the Ultrasonic drying system (100) at a much lower cost. The yarns exiting from the drying tunnel (210) are passed through the cooling unit (211) and collected on the accumulator (212). Ultimately, the bobbin winder (213) winds the yarns here in the form of a bobbin and turns them into a final product.

[0043] 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).

[0044] The Ultrasonic drying system (100) shown in FIG. 2 is positioned between the vacuum unit (209) and drying tunnel (210). In the ultrasonic drying system (100), the water on the wet yarns (300) exiting from the vacuum unit (209) and still having more humidity than desired is removed by the Ultrasonic sound waves. The aforementioned Ultrasonic drying system (100) removes the water on the wet yarns (300) in a ratio of 90% to 99%. This ratio may be different on the basis of the yarns that are processed. While this ratio is high in the yarns which have low absorption such as polyester, it may be rather low in the natural fibrous yarns which have a higher absorption such as viscose. Since the wetness of the wet yarns (300) is substantially removed by the Ultrasonic drying system (100), they may be passed through a drying tunnel (210) which may be rather shorter than those of the present methods in order to obtain the final humidity ratio. After the drying process, the dehydrated heated yarns (400) in the drying tunnel (210) are passed through the cooling unit (211) to decrease them to the ambient temperature. The yarns are cooled by blowing ambient air onto them. Afterwards, these yarns are pulled and accumulated by the accumulator (212). The line is provided to work continuously by this accumulation process. The yarns accumulated on the accumulator (212) are wound on the spools in the form of bobbins on the bobbin winder (213) to become a final product, and the production procedure is completed. The Ultrasonic booster (101) which forms the sound waves to be transmitted to the wet yarns (300) is situated on the upper part of the aforementioned Ultrasonic drying system (100). Said Ultrasonic booster (101) is connected to a control panel (102) to set the sound waves to be transmitted. A horn (103) positioned between said Ultrasonic booster (101) and the wet yarn (300) provides the transmission of the sound waves to the wet yarn (300) bundle. The inlet idler cylinder (104) positioned in the section where the wet yarns (300) are introduced to the aforementioned Ultrasonic drying system (100) cooperates with the outlet idler roller (105) positioned in the outlet portion of the dehydrated yarns (400) and keeps the yarn bundle stretched.

[0045] 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.