SYSTEM AND METHOD FOR PROACTIVE DYEING FOR CELLULOSIC AND CELLULOSIC BLENDED TEXTILES

Abstract

A system and method for cationization of textiles preferably starting with the dry raw greige tubular or open width goods that are made from either a cellulosic or cellulosic blended fabric. The system can include an inducer apparatus with chemical dosification system. In a preferred embodiment, the dry tubular goods are sent in a flat configuration to a first impregnation tank where it receives a multi-functional reaction fluid. After leaving the first impregnation tank, the now wet fabric is turned (when in a tubular width fabric form) by a turning unit and then sent to a second impregnation tank where it again is exposed to the multi-functional reaction fluid. The turning of the fabric causes the side edge positions of the flat tubular fabric to change its physics dynamics which allows for the multi-functional reaction fluid to be evenly applied to the entire fabric. Turning is not needed for open with fabric as it is flat, thus having only one dynamic when analyzed with physics.

Claims

1. A system for cationization of textiles starting with the dry tubular width fabric that are made from either a cellulosic or cellulosic blended fabric in a raw greige stage directly from knitting for cost efficiency, or in a pre-scoured greige or pre-bleached greige condition, the system comprising: a fabric feeding unit for spreading and forwarding tubular width fabric for inducing prior to dyeing, wherein in a spread configuration the tubular fabric is forwarded in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric; a first chemical impregnation tank in communication with the fabric feeding unit and receiving the tubular width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a multi-functional reaction fluid able to treat fabric in a raw greige dirty condition or in a scoured or bleached condition; a turning unit receiving the tubular width fabric exposed to the multi-function reaction fluid after the tubular fabric exits the first chemical impregnation tank, the turning unit turning the tubular fabric at an angle to cause the location of the initial set of edges to now be substantially flat fabric and no longer at an edge position, wherein continued travel and turning of the tubular fabric causing different areas of the tubular width fabric to become a new set of edges on each side of the traveling flat tubular fabric; and a second chemical impregnation tank in communication with the turning unit, the second chemical impregnation tank receiving the turned wet tubular width fabric from the turning unit and after the turning unit has turned the wet tubular width fabric, the second chemical impregnation tank defining a second interior area containing a second amount of the multi-functional reaction fluid able to treat fabric;

2. The system for cationization of claim 1 wherein the fabric is preferably raw dry greige goods.

3. The system for cationization of claim 1 further comprising a fabric bridge leading to the turning unit, the fabric bridge having width measurement sensors and spreaders, the width measurement sensors reading any changes in width of the fabric after the fabric leaves the first impregnation bath to compensate for the dry moving fabric getting wet and thus thinner, wherein again the width measurements are used by the spreaders when guiding the fabric to prevent ripping or twisting of the fabric.

4. The system for cationization of claim 1 wherein a range for the angle is about 45-90° degrees.

5. The system for cationization of claim 1 wherein the first chemical impregnation tank is in fluid communication with the second chemical impregnation tank through a first conduit providing communication between the first interior area and the second interior area and serving as an inlet for providing the second amount of the multi-functional reaction fluid into the second interior area.

6. The system for cationization of claim 5 wherein the first chemical impregnation tank is also in fluid communication with the second chemical impregnation tank through a second conduit providing communication between the first interior area and the second interior area and serving as an outlet for returning at least some of the second amount of the multi-functional reaction fluid from the second interior area back to the first interior area in order to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area.

7. The system for cationization of claim 1 further comprising a first blowing air unit for ballooning the fabric impregnated with the multi-functional reaction fluid to increase penetration, evenness of penetration and making the fabric perfectly flat going directly into the first squeeze to prevent overlaps or twists of the wet greige fabric with the multi-functional reaction fluid after it exits the first impregnation tank and prior to being turned by the turning unit.

8. The system for cationization of claim 1 wherein the first chemical impregnation tank having a first displacing block(s) disposed within the first interior area to reduce an available volume amount within the first interior area.

9. The system for cationization of claim 8 wherein the second chemical impregnation tank having a second displacement block(s) disposed within the second interior area to reduce an available volume amount within the second interior area.

10. The system for cationization of claim 1 wherein the second chemical impregnation tank disposed at an angle with respect to a position of the first chemical impregnation tank depending on the desired degree of the turning unit and if the turning unit is place between the tanks.

11. The system for cationization of claim 1 further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer rope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention.

12. The system for cationization of claim 11 wherein the A-frame is positioned on a movable floor guided by a center winder sensor of the fabric winding assembly so that winding by the winding assembly is centered to avoid air pockets and allow for fabric edge on edge winding.

13. The system for cationization of claim 1 wherein the first impregnation tank, the turning unit and the second impregnation tank are enclosed within a housing, the housing having an exhaust fan and outlet for worker safety with a control panel place outside of an enclosed area defined by the housing.

14. The system for cationization of claim 7 further comprising a second blowing unit for ballooning the fabric impregnated with the multi-functional reaction fluid after it exits the second impregnation tank for even penetration and preventing wrinkles going into a second squeeze as width is automatically regulated by spreaders which are given current with by sensors.

15. The system for cationization of claim 1 wherein the multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric.

16. A system for cationization of textiles starting with the tubular width fabric that are made from either a cellulosic or cellulosic blended fabric, the system comprising: a fabric feeding unit for forwarding a fabric in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric; a first chemical impregnation tank in communication with the fabric feeding unit and receiving the tubular width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a multi-functional reaction fluid; a mixer having an outlet in fluid communication with the first chemical impregnation tank for introducing the cold multi-functional reaction fluid into the first interior area of the first chemical impregnation tank; a first blowing air unit for ballooning the fabric impregnated with the multi-functional reaction fluid to increase penetration, prevent wrinkles and evenness of the multi-functional reaction fluid after it exits the first impregnation tank; a first squeezing rollers unit with pressure control pistons positioned above the first air blowing unit and the first chemical impregnation tank, wherein the fabric impregnated with the multi-functional reaction fluid from the first impregnation tank is fed through and squeezed by the first squeezing rollers unit and prior to being received by a turning unit; a turning unit receiving the tubular fabric exposed to the multi-function reaction fluid after the tubular fabric exits the first chemical impregnation tank, the turning unit turning the tubular fabric at an angle to cause the location of the initial set of edges to now be approximately centrally located with respect to the substantially flat fabric and no longer at an edge position, wherein continued travel and turning of the tubular fabric causing different areas of the tubular fabric to become a new set of edges on each side of the traveling flat tubular fabric; a fabric bridge leading to the turning unit, the fabric bridge having width measurement sensors and spreaders, the width measurement sensors reading any changes in width of the fabric after the fabric leaves the first impregnation bath, wherein the width measurements are used by the spreaders when guiding the fabric to prevent ripping, wrinkling or twisting of the fabric; a second chemical impregnation tank in communication with the turning unit, the second chemical impregnation tank receiving the turned wet tubular fabric from the turning unit and after the turning unit has turned the wet tubular fabric, the second chemical impregnation tank defining a second interior area containing a second amount of the cold multi-functional reaction fluid, in fluid communication to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area; a second squeezing rollers unit positioned above the air blowing unit and the second chemical impregnation tank, wherein the fabric impregnated with the multi-functional reaction fluid from the second chemical impregnation tank is fed through and squeezed by the second squeezing rollers unit; wherein the second chemical impregnation tank disposed at an angle with respect to a position of the first chemical impregnation tank; wherein the multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric.

17. The system for cationization of claim 16 wherein the fabric to be induced is raw dry greige goods directly from the knitting or weaving department.

18. The system for cationization of claim 16 wherein the angle is between about 45-90° degree.

19. The system for cationization of claim 16 further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer tope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention.

20. A method for evenly applying a multi-functional reaction fluid to a tubular width knit fabric being fed through a cationization system in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric, the fabric being a cellulosic or cellulosic blended fabric, comprising the steps of: a. exposing a length of tubular width knit fabric to a first amount of a multi-functional chemistry solution disposed within a first inducing bath, b. turning the tubular width knit fabric after the tubular knit fabric has exited out of the first inducing bath to cause the location of the initial set of edges to now be approximately centrally located with respect to the substantially flat fabric and no longer at an edge position and also causing different areas of the tubular fabric to become a new set of edges thus creating new physics dynamics for the fabric for even distribution of chemistry on each side of the traveling flat tubular fabric; and c. exposing the tubular width knit fabric after turning, to a second amount of the multi-functional chemistry solution disposed within a second inducing bath.

21. The method for evenly applying a multi-functional reaction fluid to a tubular width knit fabric of claim 20 further comprising the step of automatically winding the fabric without human intervention by a self-catching winding assembly, the self-catching winding assembly having a winder with outwardly extending needles and an A-frame with the winding assembly rotatably connected to the winder.

22. The method for evenly applying a multi-function reaction fluid to a tubular width knit fabric of claim 21 further comprising the step of allowing the fabric to remain winded for a period of time to cause the multi-functional reaction fluid to bond to the fabric as the fluid slowly warms up and over time with further warming up of the fluid creating one or more positive charge sites on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric

23. A system for cationization of textiles starting with the open-width goods that are made from either a cellulosic or cellulosic blended fabric, the system comprising: a fabric feeding unit containing a spreader spread so the open-width fabric is forwarded in a flat configuration; a first chemical impregnation tank in communication with the fabric feeding unit and receiving the open-width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a cold multi-functional reaction fluid; a mixer having an outlet in fluid communication with the first chemical impregnation tank for introducing the cold multi-functional reaction fluid into the first interior area of the first chemical impregnation tank; a first squeezing rollers unit with pressure control pistons positioned above the first chemical impregnation tank, wherein the fabric impregnated with the cold multi-functional reaction fluid from the first impregnation tank is fed through and squeezed by the first squeezing rollers unit; a second chemical impregnation tank in communication with the fabric bridge, the second chemical impregnation tank receiving the wet open-width fabric after the fabric has left the first chemical impregnation, the first chemical impregnation tank is also in fluid communication with the second chemical impregnation tank through a second conduit providing communication between the first interior area and the second interior area and serving as an outlet for returning at least some of the second amount of the multi-functional reaction fluid from the second interior area back to the first interior area in order to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area; a second squeezing rollers unit positioned above the second chemical impregnation tank, wherein the fabric impregnated with the cold multi-functional reaction fluid from the second chemical impregnation tank is fed through and squeezed by the second squeezing rollers unit; wherein the cold multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric.

24. The system for cationization of claim 23 wherein the goods are raw dry greige goods.

25. The system for cationization of claim 23 further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer tope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention.

26. The system for cationization of claim 25 wherein the A-frame is positioned on a movable floor guided by a sensor of the fabric width on the A-frame so the pressure on the fabric winding is even and not too tight.

27. The system for cationization of claim 23 further comprising a covering to create a “closed” system and minimize or prevent exposure to an vapors created by chemical reaction of the reaction fluid; wherein further comprising a control panel for controlling operation of the system with the control disposed on an elbow arm device or mounted outside an area enclosed by the covering; wherein the tanks are enclosed by the covering and the covering is provided with an exhaust system.

28. The system for cationization of claim 27 wherein dyeing of the cationized cellulosic fabric is performed in the exhaust system and in a dyeing cycle treatment steps include washing, bleaching, dyeing, neutralization with a finishing pH of 5.7-5.9, with current chemistry and an addition of boric acid as a scent preventing agent for preventing degradation of TMA and a fishy smell often appearing during standard textile drying.

29. The method for evenly applying a multi-function reaction fluid to a tubular width knit fabric of claim 20 wherein an ionic cross-linked cationic fibrous material in the raw greige fabric stage directly from knitting or weaving in a practical and in a production manner though a cold pad-batch method is produced involving the following steps inducing mono functional or multifunctional cationic polymer with the epoxy chain attaching to the cellulosic fibers in a high alkali solution comprising a mono cationic polymer 2,3-epoxypropyl trimethyl ammonium chloride (EPTAC) with the EPTAC formed from 3-chloro-2-hydroxypropyl trimethyl ammonium chloride (CHTAC) with an alkali, sodium hydroxide (NaOH) and providing boric acid in a dyeing process to prevent TMA degradation and prevent a permanent fishy smell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 is a perspective view of the novel cationization system in accordance with the present disclosure showing the turn of the inducer machine following the turning of the fabric direction by the mechanism which rotates the fabric here about 90 degrees;

[0044] FIG. 2 is another perspective view of the novel cationization system in accordance with the present disclosure showing the A-Frame with needles positioning;

[0045] FIG. 3 is a perspective view of one non-limiting embodiment for the fabric self-catching needles of the winding assembly in the process of catching raw greige tubular fabric coming out of inducing stage in accordance with the present disclosure;

[0046] FIG. 4 is a perspective view of one non-limiting embodiment for the fabric self-catching needles of the winding assembly with raw induced greige tubular fabric in accordance with the present disclosure;

[0047] FIG. 5 is a perspective view of the novel cationization system enclosed to form a “closed” system and showing self-catching needle A-Frame in accordance with the present disclosure;

[0048] FIG. 6 is a perspective view of the novel cationization system showing the fabric being turned after the first bath being and then being fed into the second bath and with the squeezing rollers positioned above the second in accordance with present disclosure; and

[0049] FIG. 7 is a side view of the novel open width cationization system showing the open fabric being wound on a self-catching A-Frame and moving away from the inducing machine as the impregnate raw greige fabric make the roll larger and the platform moves the A-frame future from the inducer so that the induced fabric has even pressure and tension during the in accordance with the present disclosure.

DETAILED DESCRIPTION

[0050] The disclosed and shown system and method, provides for anionic fibrous material with cationic reactive groups. Preferably, the anionic fibrous material can be cellulose or cellulosic blended fabric, which can be in the raw greige stage directly from the knitting process. The raw greige fabric could be pre-treated by being scoured or beached but is not preferred as it increases the cost of the dyed end fabric. The fabric is in dry condition and can be in rolls or in flat form. Through use of the system/method, the cellulosic or cellulosic blended fibrous fabric is first padded with a cold mixture of cationic reactant, water and other auxiliary chemicals, winded up on a self-catching A-frame, sealed air tight preferably with a plastic or other air tight material and packed with plastic tape and patched for a period to form the cationic cellulose.

[0051] Preferably, padding comprises padding a cold EPTAC chemical though dosing on the cellulose or cellulosic blended fabric through an inducing bath/tank containing EPTAC that is formed by a chemical reaction between CHPTAC and Caustic-Soda. Nonionic wetting, sequestrant detergent, cracking agents and a scent reaction preventing agent can also be included in the chemical bath, so that the fabric absorbs the chemical bath more quickly and without odor.

[0052] As seen in the Figures the fabric is fed through the various components of the novel system by various rollers, conveyors and/or pads located throughout the system.

[0053] The padding unit or the impregnation tank can be designed for an extended fabric/chemical contact time. As best seen in FIG. 6, the inducing bath/tank can have a narrow design with a relatively low fluid volume, preferably through the positioning of a displacement block within the tank.

[0054] The reaction fluid can be preferably fed through a single pipe system from the mixer into the first impregnation tank (where the system includes multiple tanks/baths). Preferably, Preferably, the bath temperature for the fluid in the impregnation tank is set to about 16° C. to about 30° C. Grad Celsius, however other temperatures and temperature ranges can be used and are considered within the scope of the disclosure. The chemical bath can have a constant temperature range of 16° C. to about 30° C.

[0055] A pump system can also be provided to constantly move the fluid inside the bath/tank and constantly mix the fluid with new fluid coming into the tank either from the mixer or from another tank.

[0056] After passing the fabric trough the impregnation tank, the fabric can be squeezed by squeezing rollers positioned above the tan (See FIG. 6) to a pick up from a preferred minimum of about 50% to a preferred maximum of about 120%. In the preferred embodiment, the chemical bath pick-up can be constant throughout the production of the same batch of fabric to ensure uniform color retention during the dyeing phase. The squeezing rollers can with a shore hardness of about 75 to about 95. The underlining roll can be the driving roll and the upper roll can be the pressure adjustable roll. The squeezing pressure can be adjusted by regulating the air-pressure on the cylinders from about 1-about 7 bar, according to the required squeezing effect.

[0057] Preferably, the inducing tank(s) and their squeezing unit(s) are sealed up and covered by an enclosure preferably having an exhaust system (See FIG. 4).

[0058] To eliminate or reduce migration and contact between the treated fabric and the air, the induced fabric once finished with the cationization system can be air tight packed with plastic and sealed. The treated fabric is preferably stored for 12 to 24 hours to allow the reaction between the cellulose or cellulosic blend and the EPTAC to take place.

[0059] The cationization system (inducer) is preferably a closed machine system (see FIG. 5), having a novel injection and dosification system, tension, bath level, pressure, temperature and speed control. Preferably, the system can have a double padder and two fluid baths which are specially designed to achieve a relatively long contact time with the liquor/chemistry. A novel spreading unit is also provided which direct/turns the fabric about 45- 90° to create a new edge on the flat part of the fabric while inducing tubular fabric.

[0060] The preferred two-inducing baths can be preferably connected with a pipe system in which the two-fluid bath are preferably constantly exchanging and passing the reaction fluid.

[0061] Preferably, under the squeezing rollers can be provided with a collecting trough for collecting dripping fluid caused by the squeezing of the fabric which return the collected fluid back into the bath/tank.

[0062] On the top of the inducer system a cover/enclosure can be provided for the fumes and vapor of the bath(s), preferably with an aspiration system.

[0063] A winder assembly is provided at the exit of the machine (See FIG. 1) which can comprise a winder column with axial system installed for a center winder A-Frame. The wind-up of the fabric on the novel A-Frame can be controlled over tension measurements depending on the diameter of the fabric roll. With an installed potentiometer the speed of the winder column can be regulated, depending on the fabric roll size.

[0064] On top of the padder and winder a cover can be installed to extract all the fumes, which are produced in the process and thus allowing the system to be considered a “closed” system. As seen in FIG. 5, a clear PVC curtain can preferably be installed from top to the floor to keep the area associated with the winding system closed.

[0065] The treated fabric passes over a conveyer to the exit and the fabric is rolled up on a center A-Frame. To minimize or eliminate human touching of the fabric during operation, particularly where the fabric may be induced with aggressive chemicals, the winding assembly can be self-catching and receives the fabric without human intervention or contact of the fabric. In one non-limiting embodiment, the outer surface can be provided with a plurality of outwardly extending needles to catch the fabric. The needles can be in the form of a needle carpet (See FIGS. 2,3,4 and 5).

[0066] Preferably at the end of a conveyor at or adjacent to the winding assembly can be provide a cutting unit for automatically cutting the fabric at the end conveyor preferably after a predefined length of fabric has passed. The automatic cutting again eliminates or reduces the need for human contact with the fabric induced with the chemicals. The cutting system can pass horizontal guides from the right to the left or reverse and cut the fabric after the desired meter/length production of fabric has been achieved.

[0067] The A-fame core, where the fabric is winded, can be attached preferably with a stainless-steel zig, zag carpet. The needles can be preferably formed with a little hook on the top for grabbing the beginning of the fabric. To support this self-catching system, a swing roll, can be installed in this area pushing the fabric onto the needle carpet. The needle tape can be tabbed or otherwise secure on or to the cylinder of the A-frame.

[0068] The tubular or open width fabric can be 100% cotton or a cellulosic blends of fibers ut preferably of at least about 30% cotton.

[0069] During use of the tubular width fabric system, preferably a plurality of individual tubular width fabric rolls can be sewn together end to beginning for continuity processing of fabric through the system. Open width fabric can also be sewn together if it is fed to the inducer in a plaited format in buggies with a tail the end of the container plaited fabric hanging out of the buggy, so that the process can be continuous.

[0070] The knit fabric can be raw greige fabric directly from knitting, prebleached, pre-scoured or enzymatic treated. The fabric is in dry condition and can be in rolls or in flat form. The fabric is placed at the entry of the machine preferably in a trolley or pallet, so the fabric can be pulled with relatively little resistance to begin the process.

[0071] The fabric can be center set and spreaded with a spreading unit 30. This center set and spreading unit can be placed in many areas of the inducer. The turning unit, which preferably provides for a 45° to preferably 90° turn of the fabric is placed in this tubular inducer between the 2 bath units.

[0072] As seen in FIG. 6, after being turned, the fabric can be transported to a second impregnation tank 34, past trough a second ballooning system 35, a second spreading unit 36 and a second squeezing unit 37. With ae second transfer unit 38, the fabric can be transported tensionless to the exit of the inducing machine/system. Also, at the exit, an automatic cutting device 40 is recommended for automatically cutting the fabric after a certain length of fabric has passed through and without human contact of the fabric. A center A-frame winder 41 can be coupled with a stationary motor 42 for driving the winder. A swing roll unit 43 can be provided for pushing the fabric to the A-frame cylinder via the self-catching needle tape carpet 44.

[0073] With the open width fabric system/inducer, a centering unit at the entry of the foulard can be installed. A tension control unit at the entry and a padder can be installed to help ensure the same width of the fabric through the impregnation process. A tension control unit at the exit of the padder and the winder assembly can be installed to ensure the same width of the fabric and an even roll up on the A-Frame (see FIG. 7).

[0074] Two uncurling spiral rollers can be installed, with one unit in the entrance and the second after the fluid bath, before the squeezing unit, to ensure no edge curling of the fabric. Preferably, each chemical for the reaction fluid, such as, a wetting, cracking, dispersing agent, caustic-soda, the scent stopping agent boric acid and the cationic reactant can be dossified separate and mixed with a mixer with the chilled water before the entry of the mixed reaction fluid into the first chemical tank/bath.

[0075] The pre-treated, washed fibrous assemblies are then dyed preferably with any anionic dye. Any of the known types of anionic dyes can be suitably employed in this process. Preferably, the dyestuffs include at least one dye selected from the group comprising of direct dyes, premetallized dyes, acid dyes, sulfur dyes, vat dyes, pigment dyes, reactive dyes and natural dyes. The specific dyestuffs used may be selected depending upon the type of fabric used, the particular color desired and/or other considerations.

[0076] Some of the features, benefits and/or advantages provided by the disclosed novel open width and tubular width fabric systems and methods can include, without limitation, the following:

[0077] 1. Provides an apparatus and application system for a semi-continuous or continuous open width and a tubular width continuous or semi continuous treatment of knit fibrous material of cellulosic fibers, containing a cationic polymer, wherein the ionic cross-linked fiber can be dyed in a stronger, faster, and ecologic manner.

[0078] 2. The fibrous material compromises preferably raw greige although pre-bleached or pre-scoured piece goods in tubular or open width knit form are applicable to this method. The piece goods are cellulose fibers and cellulose blended fibers.

[0079] 3. The circular-knit fabric is in dry stage.

[0080] 4. The dyeing of cellulosic fiber can include anionic dyestuffs, without the usage of salt.

[0081] 5. Producing an ionic cross-linked cationic fibrous material in the raw greige fabric stage directly from knitting or weaving in a practical and in a production manner in a cold pad-batch method. The method can include the steps of inducing mono functional or multifunctional cationic polymer with the epoxy chain attaching to the cellulosic fibers in a high alkali solution, and an example in the mono cationic polymer 2,3-epoxypropyl trimethyl ammonium chloride (EPTAC). The EPTAC can be formed from 3-chloro-2-hydroxypropyl trimethyl ammonium chloride (CHTAC) with the alkali, sodium hydroxide (NaOH). The set of the NaOH and CHTAC concentration can depend on the desired efficiency cationization and can vary. Here the boric acid is needed in dyeing to prevent TMA degradation which causes a permanent fishy smell.

[0082] 6. Uses one or more inducing bath(s)/tank(s) which can contain in additional auxiliaries such as, without limitation, Cracking-Agent, Wetting-Agent, Sequestering Agent and/or Dispersing Agent, etc., to clean the dirty raw cotton fabric.

[0083] 7. The active cationic (EPTAC) reacts with the hydroxyl groups of the cellulose to form a permanent bond and cationic dye site.

[0084] 8. Cold Patch Padding, preferably but not limited to, the cellulosic fiber material with a wet pickup of about 50% to about 120% with squeezing rolls.

[0085] 9. Batching the cellulosic fiber material over a time period from 12 hours to 24 hours at room temperature wherein the fabric can be wrapped and sealed airtight with plastic wrap to avoid evaporation and condensation.

[0086] 10. The fluid bath(s)/tank(s) can have a narrow design and the open a tubular width knit fabric passes continuously through a preferred but not necessary relatively low volume fluid bath.

[0087] 11. The squeezing rate from the tubular wet fabric is about 50 to about 120% and the layer of the rubber from the squeezing rolls having a shore hardness of about 75 to about 95.

[0088] 12. The cylinder of the center-winder can be tapped with a stainless-steel needle tape, to provide for a fabric self-catching ability then avoiding human contact. The fabric self-catching unit can include a swing-roll to direct the fabric to the needles on the cylinder.

[0089] 13. In between the exit from the inducing system and the winder apparatus an automatic cutting unit can be installed, which can be a cross cutting device to cut the treated wet fabric from the left to the right or in reverse to avoid human intervention.

[0090] 14. Provides for a chemical dosing system with automatic settings, which can be connected to the fluid bath unit(s)/tank(s).

[0091] 15. The dosification apparatus system can include water (which can be chilled or cooled water) and chemical tanks with a polymer with one epoxy forming site and one or more cationic forming sites, Wetting Agents, Cracking Agents, Sequestering Agents and Caustic-Soda liquid. Each chemical tank can have a separate line and a separate pump system. The chemicals pre-mixed in water can be mixed together through a mixer and then getting injected together within the interior area of the first fluid bath/tank. The mixing is inline or by separate pumps depending on cost parameter, but both provide the accuracy needed. When there are two baths/tanks, a circulation pump can be provided to keep the baths homogenous.

[0092] 16. The preferred dosification apparatus system needs the incoming water temperature to be cold and consistent for the fluid reactions to be controlled.

[0093] 17. In one non-limiting embodiment, the inducing unit for tubular width knit fabric can be a two bath/tank padder, which can be laid out in a Shape, preferred from 45-90° where the angle promotes the fabric to turn changing one end to a flat surface and vice-versa (thus the turning mechanism).

[0094] 18. Between the two inducing baths/tanks for the tubular width knit fabric, a novel spreading/turning unit can preferably be installed but the spreading/turning unit can vary in position along the path of the inducer based on the fabric or factory space constraints.

[0095] 19. With the turning of the fabric, the two original edges of the flat tubular width fabric are placed in the flat of the fabric and the previous flat of the fabric is passed into or becomes the new edges to allow for an even application of the reaction fluid on the entire fabric.

[0096] 20. The turning angle can be a 45-90° degree angle and preferably 90°-degree angle, but for space constraints the range is satisfactory as to observe the turn is critical using the eye or sensors.

[0097] 21. The described inducing system is preferably covered to form a “closed” system as vapors from chemical reaction can be harmful to worker. Also, the control panel can be on an elbow arm device or mounted outside the closed area. Preferably, the inducing bath(s)/tank(s) can be totally covered and provided with an exhaust system. Preferably, a second cover having a clear PVC curtain can be installed in the up-winding area, with an additional aspiration system. The drained fluid from the inducing system can be collected in a separate tank where it can be neutralized with acid and an installed mixer and made harmless to the environment and/or to a form which the water treatment plant can easily eliminate.

[0098] 22. The dyeing of the CHTPAC cationized cellulosic fabric can be done in the exhaust system, and in one dyeing cycle: the treatment steps can include washing, bleaching, dyeing, neutralization with a finishing pH of 5.7-5.9, with the same chemistry currently used in the current commercially used process but adding a scent preventing agent, namely boric acid, as the cationizing chemistry and contains TMA groups. To prevent the degradation of the TMA and in turn a fishy smell during standard textile drying.

[0099] 23. There are other fabric dyeing systems which can be used which use reactive dyes, but exhaust systems are the only operating fabric closed dyeing system known to date, thus recommended.

[0100] 24. Producing an ionic cross-linked cationic fibrous material in the raw greige fabric stage directly from knitting or weaving in a practical and in a production manner in a cold pad-batch method. The method can include the steps of inducing mono functional or multifunctional cationic polymer with the epoxy chain attaching to the cellulosic fibers in a high alkali solution, and an example in the mono cationic polymer 2,3-epoxypropyl trimethyl ammonium chloride (EPTAC). The EPTAC can be formed from 3-chloro-2-hydroxypropyl trimethyl ammonium chloride (CHTAC) with the alkali, sodium hydroxide (NaOH). The set of the NaOH and CHTAC concentration can depend on the desired efficiency cationization and can vary. Here the boric acid is provided in dyeing to prevent TMA degradation which causes a permanent fishy smell.

[0101] 25. More than one turn can be incorporated into the system depending on the fabric. Thus, the system can have one turn, two turns, etc. depending on the fabric. It within the scope of the disclosure to place the turn anywhere in the path of the inducing machine.

[0102] 26. The multi-functional reaction fluid can be a cold multi-functional reaction fluid.

[0103] All measurements, dimensions, chemicals, ingredients, shapes, amounts, angles, values, percentages, materials, degrees, configurations, orientations, time periods, product layout, components or parts; component or part locations, sizes, number of sections, number of components or parts, etc. discussed above or shown in the Figures are merely by way of example and are not considered limiting and other measurements, dimensions, chemicals, ingredients, shapes, amounts, angles, values, percentages, materials, degrees, configuration, orientations, time periods, product layout, components or parts, component or part locations, sizes, number of sections, number of components or parts, etc. can be chosen and used and all are considered within the scope of the invention.

[0104] It will be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description shall be interpreted as illustrative and not in a limiting sense. The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment.

[0105] It should be understood that the exemplary embodiments described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each embodiment should typically be considered as available for other similar features or aspects in other embodiments. While one or more embodiments have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from their spirit and scope.

[0106] Unless feature(s), part(s), component(s), characteristic(s) or function(s) described in the specification or shown in the drawings for a claim element, claim step or claim term specifically appear in the claim with the claim element, claim step or claim term, then the inventor does not consider such feature(s), part(s), component(s), characteristic(s) or function(s) to be included for the claim element, claim step or claim term in the claim when and if the claim element, claim step or claim term is examined, interpreted or construed. Similarly, with respect to any “means for” elements in the claims, the inventor considers such language to require only the minimal amount of features, components, steps, or parts from the specification to achieve the function of the “means for” language and not all of the features, components, steps or parts describe in the specification that are related to the function of the “means for” language.

[0107] Dimensions and/or proportions of certain parts in the figures may have been modified and/or exaggerated for the purpose of clarity of illustration and are not considered limiting.

[0108] While the system and method has been described and disclosed in certain terms and has disclosed certain embodiments or modifications, persons skilled in the art who have acquainted themselves with the disclosure, will appreciate that it is not necessarily limited by such terms, nor to the specific embodiments and modification disclosed herein. Thus, a wide variety of alternatives, suggested by the teachings herein, can be practiced without departing from the spirit of the disclosure, and rights to such alternatives are particularly reserved and considered within the scope of the disclosure.