SYSTEMS, METHODS, AND MACHINE FOR METALLIZATION OF FABRIC

Abstract

Systems and methods, as well as a machine, which can be used to improve constancy of fabric exposure to chemicals in a liquid bath and particular in the process of metallization. These systems and methods can be used to provide for more effective batch processing of fabric but can also be linked together to provide for what is effectively a continuous process as well.

Claims

1. A method for treating a length of fabric, the method comprising: providing a chemical bath divided among a plurality of shallow trays positioned on a frame; feeding a first end of said length of fabric over a first roller and into said chemical bath in a first tray in said plurality of trays; keeping said length of fabric suspended in said chemical bath without contacting said first tray while said length of fabric traverses said first tray; directing said first end over a second roller and into said chemical bath in a second tray in said plurality of trays; keeping said length of fabric suspended in said chemical bath without contacting said second tray while said length of fabric traverses said second tray; and directing said first end over a third roller.

2. The method of claim 1, wherein said length of fabric passes through said first tray in a first direction and said second tray in an opposing second direction.

3. The method of claim 2, wherein said chemical bath in said first tray flows in a flow direction generally parallel to said first direction.

4. The method of claim 3, wherein said flow direction is in a direction generally the same as said first direction.

5. The method of claim 4, wherein said chemical bath in said second tray flows in a flow direction generally parallel to said second direction.

6. The method of claim 5, wherein said flow direction in said second tray is in a direction generally the same as said second direction.

7. The method of claim 6, wherein said flow direction in said second tray is in a direction generally opposing said second direction.

8. The method of claim 2, wherein said chemical bath in said first tray flows in a flow direction generally perpendicular to said first direction.

9. The method of claim 8, wherein said chemical bath in said second tray flows in a flow direction generally perpendicular to said second direction.

10. The method of claim 9, wherein said flow direction in said second tray is in a direction generally the same as said flow direction in said first tray.

11. The method of claim 10, wherein said flow direction in said second tray is in a direction generally opposing said flow direction in said first tray.

12. The method of claim 1, wherein said chemical bath metalizes said length of fabric.

13. The method of claim 1, wherein said first end is connected to a second opposing end of said length of fabric to form a loop.

14. The method of claim 1 wherein there is a laminar flow of said chemical bath over said length of fabric in said first tray.

15. The method of claim 1 wherein temperature of said chemical bath is generally the same in said first tray as said second tray.

16. A method for treating a length of fabric, the method comprising: providing a roll of fabric and a plurality of reactors, each of said reactors comprising a plurality of shallow trays positioned on a frame; directing a first end of said roll of fabric into a first reactor in said plurality of reactors; while in said first reactor: feeding a first end of said length of fabric over a first roller and into a chemical bath in a first tray in said plurality of trays; keeping said length of fabric suspended in said chemical bath without contacting said first tray while said length of fabric traverses said first tray; directing said first end over a second roller and into said chemical bath in a second tray in said plurality of trays; and keeping said length of fabric suspended in said chemical bath without contacting said second tray while said length of fabric traverses said second tray; directing said first end over a third roller and into a second reactor in said plurality of reactors; while in said second reactor: feeding a first end of said length of fabric over a first roller and into a chemical bath in a first tray in said plurality of trays; keeping said length of fabric suspended in said chemical bath without contacting said first tray while said length of fabric traverses said first tray; directing said first end over a second roller and into said chemical bath in a second tray in said plurality of trays; and keeping said length of fabric suspended in said chemical bath without contacting said second tray while said length of fabric traverses said second tray; and directing said first end from said plurality of reactors into a later process.

17. The method of claim 16 wherein temperature of said chemical bath is generally the same in all of said trays in all of said reactors.

18. The method of claim 16 wherein said chemical bath in all of said trays in all of said reactors is supplied from a common source.

19. The method of claim 16 wherein said later process comprises a drying process.

20. A reactor for metalizing a length of fabric, the reactor comprising: a frame; a plurality of shallow trays positioned on said frame so as to be stacked generally vertically; a chemical bath divided among said plurality of shallow trays; and a pair of rollers associated with each of said shallow trays in said plurality of trays, wherein said pair of rollers suspend said length of fabric in said chemical bath in said associated tray without said length of fabric contacting said associated tray while said length of fabric traverses said associated tray; wherein, after traversing a first tray in said plurality of shallow trays, said length of fabric traverses a second tray in said plurality of shallow trays.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] FIG. 1 provides a front view of an embodiment of a reactor.

[0051] FIG. 2 provides a side view of the reactor of FIG. 1.

[0052] FIG. 3 provides a top view of the reactor of FIG. 1.

[0053] FIG. 4 provides a perspective view of the reactor of FIG. 4 with a loop of fabric in place.

[0054] FIG. 5 provides a general block diagram of the layout of an embodiment of a metallization system.

[0055] FIG. 6 provides a general diagram illustrating multiple reactors arranged in series.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0056] The following detailed description and disclosure illustrates by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the disclosed systems and methods, and describes several embodiments, adaptations, variations, alternatives and uses of the disclosed systems and methods. As various changes could be made in the above constructions without departing from the scope of the disclosures, it is intended that all matters contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0057] As discussed herein, the terms thread, yarn, and fiber are often used interchangeably although those terms are often provided with specific meaning in the art. However, they are all, in some respects, the act of interconnecting filaments to form suitable materials for fabric construction. Further fabric as used herein will generally comprise any form of material made through the interconnection of any combination of filaments, threads, yarns, or fibers. Although the fabrics may be described as a woven material, this description is not intended to be limited only to weaves and woven material, those are simply a common and well understood example. Materials and fabrics within the scope of this disclosure include without limitation any materials woven, knitted, bound, bonded, crocheted, knotted, tatted, felted, braided, or otherwise formed of any type of threads, yarns, or fibers either exclusively, in combination with different threads, yarns, or fibers, or in combination with non-fabric or non-filament structures. Fabrics as contemplated herein also includes materials formed by application of heat and/or pressure to filaments or other materials. For example, and without limitation, this application includes within its scope non-woven materials made to form fabrics that are not woven or knitted, such as felts. Accordingly, as would be appreciated by a person of ordinary skill in the art, the teachings herein are applicable to fabrics made by any method known to persons of ordinary skill in the art and with any type of filament or combinations of filaments. Further, the use of the term garment as used herein is primarily to indicate any article of clothing and particularly those constructed from a fabric. However, it should be recognized that the systems and methods discussed herein can be used on other fabric objects which may not be garments (such as, but not limited to, sheets, blankets, awnings, art objects, or others), or which may occasionally be used as garments even if it is not their primary purpose.

[0058] FIGS. 1-4 provide for various views of a reactor device (100) which may be used to assist in the exposure of a fabric (501) to a chemical bath (105) primarily for the purposes of metallization. It should be recognized, however, that while the systems and methods contemplated herein may be used for metallization via chemical plating, the systems and methods may be used in other processes where exposure of a fabric (501) to chemicals in a liquid bath (201) is desirable such as, but not limited to, dying operations.

[0059] The reactor shown in FIG. 1-4 is primarily designed to provide for a batch process and is typically used in conjunction with various support elements in the metallization system (300) as shown in FIG. 5. FIG. 6 provides for an embodiment where multiple reactors (100) of FIGS. 1-4 may be arranged serially in a fashion that the flow of fabric (501) through them can create what is essentially a continuous process. The serial arrangement of FIG. 6 will also generally utilize the support elements of FIG. 5, but those elements do not necessarily need to be duplicated for each reactor (100), but instead may be provided in a reduced number in the continuous arrangement with a single copy of different support elements serving multiple or all the reactors (100) in the series. An embodiment such as that of FIG. 6 can also be part of a large continuous flow with process connected to it upstream, downstream, or both. For example, input into the arrangement of FIG. 6 may be provided from a continuous pre-treatment process and FIG. 6 can output resultant metalized fabric to a post-treatment process.

[0060] The reactor of FIGS. 1-4 is generally built to provide a frame (103) which supports a number of relatively shallow trays (101) or troughs which house the chemical bath (105) in their internal volume (111) during fabric (501) exposure. The volume (111) is generally designed to allow a specific flow and movement of the bath (105) within the volume (111) of the tray (101). The fabric (501) is also typically moved through the bath (105) in the volume (111) of the tray (101) in a general laminar fashion. Thus, the fabric (501), when in the bath (105) within any individual tray (101) will typically be arranged in a generally planar fashion with generally no folds or rolls and will be within the material of the bath (105).

[0061] In order to provide for efficient use of the space, the tray (101) is not a single large tray, but is one of a plurality of similar or identical trays (101) arranged on the frame (103). In the embodiment of FIGS. 4-7, the trays (101) are arranged generally vertically, one above the other in a stacked arrangement. As should be apparent, this arrangement provides for a resultant horizontal distance within the composite volumes (111), which is where the fabric (501) may be submerged in the bath (105), which is equivalent to a much longer horizontal arrangement, but which takes less horizontal space.

[0062] The fabric (501) to be metalized or otherwise exposed to the bath (105) is typically provided on a roll or similar storage mechanism. The fabric (501) will generally be unrolled and threaded through a series of carrier rollers (107) also mounted on the frame (103). As best shown in FIG. 7, the fabric (501) when positioned on the rollers (107) will be arranged so as to move generally horizontally through the bath (105) in each tray (101) with each layer of fabric (501) moving in an opposing direction to the one immediately above and below it. The fabric (501) then moves generally vertically as it transitions from between one tray (101) to another. Typically, fabric (501) flow will be chosen so that the fabric (501) will move through the uppermost tray (101) first and the lowermost tray (101) last, but that is by no means required and in alternative embodiments the fabric flow may be reversed so as to flow from the lowermost tray (101) to the uppermost (101). In still further embodiments, fabric (501) flow may be any other desired arrangement and can include, for example, flows where certain trays (101) are used a different number of times on particular fabric (501) than others, where certain trays are bypassed, or where multiple fabrics are run through the same frame (103) simultaneously are all possible.

[0063] In such an embodiment as depicted in FIG. 4, once movement through the lowest tray (101) is completed, the fabric (501) will typically be worked through another set of carrier rollers (107) which will direct it into a larger generally vertical climb which will place it at the point of the start of the highest tray (101), where it will begin and complete the same path again. In order to provide for movement of the entire roll of fabric (501) through all the trays (101) a repeated number of times, the fabric (501) may have its ends connected so as to form one continuous loop as illustrated in FIG. 4. It should be noted that depending on the length of the loop of fabric (501), it may be necessary or desirable to have the loop of fabric (501) pass over additional rollers (107) not depicted in the FIGS. which can act as a holding system for fabric not directly involved in the immediate bath (105) exposure.

[0064] Based on the embodiment of the reactor (100) shown in FIGS. 1-4, it should be apparent how exposure of the fabric (501) (regardless of how that fabric may be constructed) to the bath (105) generally works. Firstly, the exposure of the fabric (501) to the bath (105) in each tray (101) is essentially the same as in any other tray, the only major difference between the exposure in the various trays (101) being the direction that the fabric (105) moves relative to the tray (101) with generally half (give or take one) of the trays (101) having movement of the fabric through them in a first direction and the other half (give or take one) being in the opposite direction.

[0065] While in the volume (111) of the tray (101), the fabric (501) is typically not in contact with a roller (107) or any other surface. While the fabric (501) will typically not be taunt between the rollers (107) arranged at opposing ends of the tray (101), the fabric (501) will also typically not have sufficient slack so as to be able to contact the bottom (113) of the tray (101). The fabric (501) will, thus, be suspended in the shallow volume (111) with some of the fluid of the bath (105) arranged above and below it.

[0066] The geometry of the tray (101) and the interrelationship geometry of the tray (101), fabric (501), and bath (105) may be specifically designed to maximize the time that the fabric is exposed to the bath (105) and the way the solution of the bath (105) in in contact with the fabric (501). Further, the relative geometry may also serve to specifically create laminar flow of the solution of the bath (105) across the fabric (501) while reducing or eliminating the possibility of air entrapment and/or the generation of foam. In order to provide for such effects, the specific geometry may be selected based on the specific nature of the fabric (501) being treated and the specific metal or other components of the bath (105) being used for treatment. Thus, the specific design of a tray (101) and how the fabric (501) enters the tray, for example, may be different for a particularly voluminous and fluffy fabric than it is for a smoother more planar fabric.

[0067] The fluid forming the bath (105) in the tray (101) will also typically not be static but will instead be arranged to have a particular flow within the tray (101). In an embodiment, the flow may be generally parallel to the flow of the fabric (105) in the tray (101). It may be in either direction such as with the flow of the fabric (105) or in the opposing direction. It may also be different depending on the specific tray (101). In an alternative embodiment, the flow of the fluid (105) in the tray (101) may be in a generally perpendicular direction to the flow of the fabric (501). Again, the flow may be in the same direction across the trays (101) or may be different depending on the specific tray (101). Having a consistent flow speed of both fabric (501) and fluid bath (105) results in fairly fine control of the velocity of fluid (105) passage over the surface of the fabric (501). This can then be selected for optimum crystal formation.

[0068] The movement of the fluid (105) and the fabric (501) within the volume (111) of the tray (101) will typically serve to provide for a number of additional benefits as well. In particular, the fabric (501) will typically have minimal, if any, folds, creases, wrinkles, or pockets in its structure. This can increase the uniformity of filament exposure to the bath (105). Further, having the fluid (105) within the tray (101) flow through the volume (111) in a generally laminar fashion can create a specific circulation pattern within the tray (101) which can be generally known and, thus, serve to control the fluid (105) exposure and eliminate unexpected or unknown turbulence or vortex formation in the fluid (105). Further, the generally shallow depth of the volume (111) of the tray (101) and positioning of the fabric within the depth can serve to provide a specific level of bath (105) exposure without large excesses of fluid (105) being necessary and can avoid air or foam entrapment by the fabric (501) which can also improve the consistency of fluid (105) exposure.

[0069] In different embodiments, different mechanisms may be used to supply the bath (105) to the tray (101). For example, in a simple arrangement, the fluid (105) may be simply supplied through a connected hose which discharges into one end of the tray (101) or the other. However, far more sophisticated mechanisms may be used on other embodiments to alter bath (105) exposure. For example, sophisticated discharge arrangements utilizing multiple ports of entry into the tray (101) may be used to induce particular flows within the tray. Further, fluid (105) may be supplied above or below existing fluid (105) levels in the tray (101) to either cause air mixing of the fluid (105) or to avoid it. Such alternative methods of distribution can include, for example specific spray heads that distribute new or returning fluid into the tray (105) according to a particular stream or droplet distribution pattern.

[0070] As shown in FIG. 5, the reactor (100) is typically supported by a variety of other devices in a metallization system (300). Specifically, the material of the bath (105) will typically be controlled by a return and mixing tank system (400). This system (400) comprises a mixing tank (401) which serves to supply the main source of fluid (105) to each tray (101). Once the fluid (105) has passed through a tray (101), via the flow as contemplated above, it will typically be returned to the mixing tank (401) via a return tank (403). The return tank (403) will feed returned fluid (105) to the mixing tank (401) where it may be mixed with existing stored fluid (105) present in mixing tank (401). Additional chemicals may be supplied to the fluid (105) in the mixing tank (401), in an embodiment, to maintain the fluid going to the trays (101) at a generally consistent chemistry. In such an arrangement, new fluid (105) will be provided to an inlet into the tray (101) which is of expected chemistry and fluid (105) which has passed over the fabric (501) will not be lost but reused by the process preserving raw materials. As would be understood, there may be piping (405) including relevant valves and other structures to interconnect all the various components and provide the desired fluid (105) flow.

[0071] As contemplated above, discharged fluid from all the trays (101) will generally be returned to a single return tank (403). Once there, the chemical composition of the fluid (105) may be determined through included sensors or similar devices. This may be used to alter mechanical properties of the reactor (100) (e.g. to alter the speed of fluid (105) flow through the various trays (101)) as the composition changes or the chemical composition of the returned fluid (105) may be altered so as to return the resultant composition to within certain preset values within the mixing tank (401).

[0072] Regardless of the option selected, the fluid (105) is sent out and returned to the trays (101) in a consistent known fashion. As this process of returning, mixing of fluid (105) from the various trays (101), mixing of returned fluid (105) with stored fluid (105), and return of the fluid (105) to the trays (101) can happen essentially continuously, it should be apparent that the fluid (105) entering each tray (101) may be generally the same as any other tray (101). Further, the fluid (105) composition within each tray (101) may stay generally constant over time or at least alter in a known fashion. Thus, the composition of the bath (105) to which any part of the fabric (501) in any tray (101) at any time is exposed to is generally known and may be consistent across time and tray (101).

[0073] In addition to control of the chemical composition of the fluid (105) in the tray (101), the temperature of the bath (105) may also be controlled by a temperature process control system (500). This system (500) is designed so that the fluid (105), when provided to each tray (101), goes out at a consistent temperature (typically within a range) which further improves uniformity of the bath (105) between trays (101) and over time and may allow the metallization process to operate at preferred temperature values.

[0074] While FIGS. 1-5 provide for a single reactor (100) where the fabric (501) feed is formed into a continuous loop to provide for the fabric to pass through each tray multiple times before it is removed and sent elsewhere, FIG. 6 provides for an embodiment where multiple reactors (100) are arranged in series. This allows for the fabric (501) to be sent through the reactor (100) series a single time to complete the entire metallization process instead of passing through a single reactor (100) multiple times. This can eliminate the need to form the fabric (501) into a loop. The fabric (501) may then be followed through the series of reactors (100) by another piece of fabric (501) which may be attached at its leading end to the trailing end of the first piece of fabric creating what is essentially a continuous process (or at least a continuous batch process) of metallization. Once the metallization is completed, the fabric (501) may be transferred to other processes, such as, but not limited to, drying processes, by any means, method, or apparatus known now or later discovered.

[0075] In the embodiment of FIG. 6, a single return and mixing tank system (400) and a single temperature control system (500) as shown in FIG. 5 may be used to supply the bath (105) material to all the reactors (100). This means that the material in all the trays (101) in all the reactors (100) may be substantially the same. Alternatively, a single tank system (400) and temperature control system (500) may operate on some subset of reactors (100) or on a single reactor (100). The operated subsets do not need to align and, thus, a single temperature control system (500), for example, could operate on the same reactors as multiple tank systems (400). Thus, even in the continuous process of FIG. 6, the exposure of the fabric (501) to the chemicals in the bath (105) can be made very consistent which will typically produce a more consistent metallization of the fabric at reduced time and expense.

[0076] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.

[0077] It will further be understood that any of the ranges, values, properties, or characteristics given for any single component of the present disclosure can be used interchangeably with any ranges, values, properties, or characteristics given for any of the other components of the disclosure, where compatible, to form an embodiment having defined values for each of the components, as given herein throughout. Further, ranges provided for a genus or a category can also be applied to species within the genus or members of the category unless otherwise noted.

[0078] Finally, the qualifier generally, and similar qualifiers as used in the present case, would be understood by one of ordinary skill in the art to accommodate recognizable attempts to conform a device to the qualified term, which may nevertheless fall short of doing so. This is because terms such as rectangular are purely geometric constructs and no real-world component is a true rectangular in the geometric sense. Variations from geometric and mathematical descriptions are unavoidable due to, among other things, manufacturing tolerances resulting in shape variations, defects and imperfections, non-uniform thermal expansion, and natural wear. Moreover, there exists for every object a level of magnification at which geometric and mathematical descriptors fail due to the nature of matter. One of ordinary skill would thus understand the term generally and relationships contemplated herein regardless of the inclusion of such qualifiers to include a range of variations from the literal geometric or other meaning of the term in view of these and other considerations.