Machine to simultaneously hot-press, print, flock imprint and brush

OBJECT OF THE INVENTION

The present Patent Application intends to register a machine to simultaneously hot-press, print, flock imprint and brush to obtain a decorative fabric perfectly combining printed and flocked designed effects, allowing both actions to be carried out in a single process permitting the simultaneity of the two processes and moreover, allowing other preparation and conditioning processes of the fabric to obtain a high quality in the surface finish thereof. More specifically, the new invention consists of a continuous process for the uninterrupted execution of the mentioned operations with a perfect match between them, without the production of defects or anomalies, in a single machine.

BACKGROUND OF THE INVENTION

At present, there are several fabrics on the market having printed and flocked finishes. These fabrics are manufactured in different printing and flocking processes, besides intermediate hot-pressing, brushing, drying, imprinting processes, etc. The preparation of said fabrics involves numerous disadvantages and problems, due to their complicated logistics, quality, lack of matching between the printed and flocked design effects, given that the two functions are performed by means of different processes, not permitting the printed design effects to accompany, surround, complete in their shapes, profiles, etc., the shapes, profiles, etc. of the flocked design effect, such that the final fabric reaching the consumer has the drawback of having a decoration with no matching between the printed and flocked design effects.

Another drawback of printing in the textile sector is the preparation of said fabrics for their elaboration, since, for example, the fabrics have to go through a hot-pressing process, prior to the printing process. Likewise, in the flocked fabric sector goffering of the flocked surfaces is involved for decoration processes.

In fact, the conventional process used obliges fabrics to suffer different processes in different machines, involving transport and waits between them, a fact that increases manufacturing costs and the plant area necessary with the resulting loss of quality, due to the bad match of figures between printed and flocked design effects.

DESCRIPTION OF THE INVENTION

The machine to simultaneously hot-press, print, flock, imprint and brush object of the present application, is characterised in that it performs in a single continuous process, all the steps performed over the base material, with perfect synchronisation between said different steps, including fabric preparation operations, prior to one of the main operations and cleaning operations, with elimination of the residues. In other words, the machine performs the following processes:

• Application of the background colour. In this process the fabric is subjected to the application of background treatments, like sizing, closure of pores due to being too open, fireproofing and/or anti-stain treatments.
• Drying of the previous treatments so that the fabric commences the printing process.
• Hot-pressing of the fabric before the printing process. In this process, the fabric is smoothened and wrinkles eliminated so as not to produce defects and folds in the printing.
• Consecutive printing of colours with the rotary cylinder system and colour paste to obtain a clear definition to avoid - saturation of colours between areas of different hues.
• Application of the adhesive by means of a cylinder and adhesive paste. There are perforations around the cylinder corresponding to the flock design on the fabric.
• Flocking by means of electrostatic distribution. In this process, flocking is carried out by means of an electrostatic flocking mechanism with a fabric sieve which controls flock distribution, across the entire width and a second electrostatic grid which charges the filaments positively, so they are orientated vertically with the negatively charged adhesive. This way of distributing the flock eliminates the negative effect of the free fall of the filament and moreover, produces a better finish.
• Suction of surplus flock. Given that the amount of flock supplied is less, the surplus may be eliminated by suction to resend it to the dispensing and recycling system. Moreover, as commented, the adhered flock is arranged vertically and is more resistant than the fibre deposited in the areas without adhesive, so that cleanliness is greater.
• Drying and heat setting process of the flock in the adhesive in an oven. This process is performed continuously using a pin stenter system, tensing the textile and preventing the formation of wrinkles in the flocking.
• Departure from oven and textile cooling. Once the fabric has left the oven, the flocking is still weak due to the temperature and may suffer deformations due to treading or contact. For this purpose, it is made to pass through some cylinders cooled by water and the contact of the continuous fabric with said cylinders gives the force and resistance to the flocking increasing its rigidity.
• Continuous smooth brushing. A final brushing of the totally finished surface to eliminate possible remains and to check quality.
• Rolling of the fabric and preparation for its dispatch. Since the fabric is cold and clean, there is no problem of introducing defects by contact or similar, such that rolling may be performed directly.

The machine of new invention permits the preparation of printed and flocked fabrics in a single continuous manufacturing process, permitting better quality to be obtained, elimination of errors and a better harnessing of the raw materials. In fact, for such a purpose, novel technical solutions have been adopted. Generally speaking, the colorants and liquid adhesives have been replaced by colour and adhesive pastes, resulting in less diffusion of their application over the fabric. This technical solution is an advantage, because the limits between colour and adhesive areas are more defined, preventing the saturation effect which obliges the use of liquid products. Moreover, the circulation of wet fabric through the machine is prevented, requiring shorter drying times.

Initially, the machine has a textile accumulator keeping a certain margin of fabric ready to enter in the preparation processes. Said fabric accumulator is fed by the fabric or raw material reel and permits the machine to continue operating when the reel is changed. This accumulator has some pressure cylinders at its entrance and some separated cylinder frames between which the textile is arranged in an accordion manner. The pressure cylinders may, at a given moment, stop the entrance of fabric to the machine and facilitate the union of the next reel, the machine consuming the accumulated fabric. At the exit of the fabric accumulator, there is a bottom-coating and/or fabric treatment application device. The latter obliges the main background colour and possible treatments, such as anti-stain protection, fire resistance substances or paste, to close the fabric pores and which improves print application. As has been mentioned, the device uses substances in a paste form, offering three means of applying the substance that may be used indistinctly depending on the finish desired. One application means, consists of a pitched knife, over the fabric, such that the paste is applied over the entire fabric surface. A second pitched knife exists touching the fabric surface whose use is applicable when a lower dose of the treatment is desired. Finally, the device permits a rotary cylinder to be used around in whose contour a drawing or specific design is engraved. This cylinder has the application paste in its interior where there is a knife pushing said paste through the perforated contour of the cylinder against the fabric for its application.

The next stage consists of a continuous oven dryer to fix the bottom-coating, the background colour or pore closing treatment applied in the previous device. Said oven also eliminates any humidity and matures the application of additives to prevent the flock applied later to adhere in an undesired manner.

Then, and prior to the printing process, is the hot-pressing stage to eliminate possible wrinkles and to smoothen the fabric. The hot-pressing process is performed by passing the still hot fabric through two pressure cylinders. The fabric is introduced between both and under pressure, pressing is performed, as well as compacting of the different possibilities of additive application executed over said fabric.

After pressing, there is a cooling stage, consisting of a pair of cylinders in whose interior water at 5°C to 10°C circulates.

Afterwards, we find the printing stage. The latter consists of a lattice apron over a longitudinal bedplate. To the lattice apron, a layer of adhesive is applied not leaving residues on the fabric and which is removed later. Said adhesive fixes the fabric over the apron to prevent movements during print application. The adhesive is applied when the lattice apron circulates through the lower part of the bedplate, at the return of the fabric. The latter is stuck by contact remaining fixed during all its run until removed at the end of the bedplate. The apron is cleaned with brushes and water in an operation prior to the application of a new layer of adhesive.

The printing cylinders are over the lattice apron, in a number corresponding to the colours to be applied. All the cylinders are independently motorised and have an initial setting memory to achieve matching of colours from the first meter. The cylinder train arranged over the lattice apron has as a last device, the adhesive dispensing cylinder for the flock, the surface of said cylinder configured with the engraving of the drawing desired.

Once the fabric leaves the printing stage, it passes to the flocking stage. It passes between both devices and detaches from the lattice apron which transported it in the printing bedplate and is again collected by a pin stenter fastening system, which optionally may be a clip system. The mentioned flocking stage consists of a closed bedplate, except the entry and exit of the fabric band and is conditioned by an air conditioning system maintaining its interior at a constant temperature and humidity for the correct diffusion of flock. The transport system across the entire flocking area is by pin stenter fastening, which are stuck into the fabric keeping it tense and smooth during its passage through the stage until it is detached on the opposite side. Said pin stenter permits the fabric to be tensed at its ends and in its entire length having a series of non-cylindrical, rotating transverse bars to shake the fabric. Over the circulating fabric band, one or several flock dispensing devices are arranged.

Said dispensers operate according to an electrostatic system permitting the flock to be adhered vertically over the adhesive, improving the presentation and resistance to wear and abuse. Each dispenser consists of a hopper containing flock, having in its interior two rotary dispensing cylinders to a distribution blade. The flock falls on a fabric sieve and is uniformly dispersed. Below the fabric sieve, there is an electrostatic grid which charges the flock filaments with an electric charge, making them orientate vertically with respect to the charge communicated to the fabric passing below. The flock which falls under gravity is stuck to the adhesive in a vertical position, in search of the discharge. Preferably, the flocking stage has three flock dispensers in series and a free dispensing area, there being throughout its length, shaking transverse bars for a correct distribution and interlocking of the flock.

At the exit of the stage, there are preferably, two aspirators applied over the fabric band to suck the non-adhered flock and resend it to the dispensing hoppers for recycling.

After application and dispensing of the fabric flock, if desired, it is submitted to goffering or engraving. The engraving device arranged at the flocking stage exit consists of a cylinder pressed over a countercylinder, there being on the surface of the upper cylinder a drawing in relief corresponding to the tread to be given to the flock, the adhesive still being soft to provide determined drawings and orientations of the hair. This pressure is applied in a controlled manner, the distance between both cylinders being pitched.

Afterwards, the soft flock is fastened in a sequentially arranged continuous drying oven. Said drying oven performs the thermo-fixing operation of the flock adhesive and fixes the printing colour pastes. The drying oven stage has continuous fabric circulation by pin stenter between its entry and exit. Besides the oven has adjustable areas to achieve different temperatures along its length.

At the oven exit, there is a second cooling stage, consisting of a pair of cylinders in whose interior, cold water between 5°C and 10°C approximately, continually circulates. In this stage, the adhesive sets and definitively fixes the flock over the fabric.

After the cooling stage, we have a brushing battery. Said brushing battery consists of brushes arranged over the flocked surface and shaking bars along the back of the fabric. Next to each one of said brushes, there is an air expansion cyclone aspirator, opposite the flocked surface for the suction of loose flock, duly connected to collection bags.

Finally, a double textile roller which permits fabric cutting, when the roll reaches the desired amount of wound fabric and linking to the roller of a new roll.

The mentioned machine stages are synchronised by means of electronic, mechanical and electric synchronisms, permitting the start and simultaneous operation of the necessary stages, with the due corrections for a continuous quality production.

As has already been mentioned, in the additive application cylinders of the treatment and bottom-coating application device, in the printing stage, in the flock adhesive application cylinder an additive paste is used. Said cylinders have on their contour the corresponding drawing to be applied engraved, consisting of a plurality of small perforations through which the paste is expelled, forced by an internal longitudinal knife. Said knife is arranged next to the contact zone with the fabric, such that the paste is applied in the area of greatest close contact. All the cylinders have their own motoring with speed adjuster and position memory. The speed adjuster allows the cylinder rotation to be adjusted according to the circumference of the contour and hence, prevents non-matching of the applications as the fabric circulates through the machine. The position memory permits the cylinder to be placed in the correct angular position, when setting the machine in start or after stopping. Hence, fabric consumption is prevented in test operations, when adjusting the printing and flocking line. The paste is fed inside the cylinder by an external pump. Inside said cylinder, there is an electronic probe measuring the amount of paste inside the cylinder. As the paste is consumed, the probe detects sinking inside the cylinder, activating the feed pump until the amount of paste is controlled. This system assures that paste application is uniform at a specific pressure, obtaining correct dispensing of the additive over the fabric.

Thanks to the machine of new invention, it is possible to obtain quality fabrics comparable to those made by conventional systems like weft insertion weaving with pile threads called Chenilla threads and made with application of the Jaquard system or velvety fabrics, with significant advantages over the latter, regarding a lower final fabric weight due to the possibility of the flocking system permitting the Chenilla effect to be given by flocking and hence, permitting that it is applied on the parts of fabric which will be visible, a situation not occurring in fabrics made by Jaquard weaving, where the Chenilla thread used, either by weft or by warp, crosses in one or other direction of the fabric, being hidden on the back in the areas where it will not form part of the design or drawing desired and being visible on the parts of design or drawing desired, but conforming a greater use of this Chenilla thread and hence, a greater weight in the fabric, with the resulting greater material cost.

The lower fabric weight obtained with the process and machine of new invention, permits products to be made that may be used in the decoration of beds, like bed covers, eiderdowns, etc., where the weight is very important, due to the fact that they will be supported by people during their rest.

The advantages of this continuous process combined to the technical improvements permits significant benefits in:

• Product uniformity.
• Consistency of reproducibility
• Possibility of using a large variety of base fabrics and hence, production of a greater diversity of products, as well as price variation.
• Possibility of using finer fibres (microfibres), demanded by the market.
• High processing speed, with respect to weaving
• Competitive final product due to cheapening of production costs.
• Reliability of product and final quality

To complete the description below and to permit a better understanding of its characteristics, a set of figures is attached to the present specification in an illustrative and non-limiting manner, where the most important details of the invention are shown.

BRIEF DESCRIPTION OF THE DRAWINGS

• Figure 1 shows a block diagram of the machine.
• Figure 2 shows a schematic elevation view of the fabric accumulator.
• Figure 3 shows a schematic elevation view of the bottom-coating colour, pore closing and additive applier.
• Figure 4 shows a schematic elevation view of the first drying oven, the hot-pressing stage and the first cooling stage.
• Figure 5 shows a schematic elevation view of the printing stage.
• Figure 6 shows a schematic elevation view of the flock dispensing stage.
• Figure 7 shows a schematic elevation view of a flock dispensing device.
• Figure 8 shows a schematic elevation view of the goffering device and the entrance to the second oven.
• Figure 9 shows a schematic elevation view of the exit from the second oven, the second cooling device, the brush battery and the double roller.

DESCRIPTION OF A PREFERRED EMBODIMENT

In the light of the mentioned figures and according to the numbering adopted, a preferred but non-limiting embodiment of the invention may be seen, which consists of a continuous machine including a fabric (4) coil (1) support, which feeds a fabric accumulator (2) , across some pressure cylinders (3). Said accumulator (2) delivers the fabric (4) to a bottom-coating colour, chemical treatment and/or pore closing applier device (5). After said device (5), there is a continuous oven dryer (9) followed by the hot-pressing stage (10) consisting of two cylinders opposite to each other, through which the fabric (4) circulates. Then, there is a first cooling stage (25) consisting of two cylinders opposite to each other, through which water cooled between 5°C and 10°C approximately, circulates. The fabric (4) circulates between the two cylinders of the stage (25) and moves towards the printing stage (14), which has over the bedplate a lattice apron (12) covered with adhesive, there being in the lower part of the lattice apron (12) an application device (13) and removal of said adhesive on the surface of lattice apron (12) at the lower return thereof. On the upper surface of the lattice apron (12), there is a series of rotary cylinders (15) for colour application, in sufficient number for the colours to be applied, arranged tangentially to the lattice apron (12), the last rotary cylinder (16) being a flock adhesive applier. Next to the printing stage (14), we find the flock dispensing stage (17) over the fabric (4) consisting of a closed bedplate with a permanent conditioning system. Said stage bedplate (17) has a fabric transport means (18) by means of pin stenter or similar, there being a series of non-cylindrical rotating bars (19) along said transport means (18) for shaking the fabric (4). Over said transport means (18), there are preferably, three electrostatic flock dispensers (20) located in the back part of the stage (17) and there being a space for simple shacking in the rear part. At the end of the transport means (18), there are two aspirators (21) for non-adhered flock, applied to the width of the fabric surface (4) and connected in discharge with the dispenser flock stores (20).

After the flock dispensing stage (17), there is a goffering device (22) consisting of a rotating engraving cylinder (31), opposite a countercylinder (11) according to a pitched separation. Between both cylinders (31 and 11) the fabric band (4) circulates.

Afterwards, there is a second drying oven (24) for thermo-fixing the flock adhesive and printing with a fabric transport means (18) by pin stenter or clips. The oven (24), has its length divided in different areas with temperature adjustable heaters (23).

After the oven (24), there is a second cooling stage (26) , consisting of two opposite cylinders, through which water cooled between 5°C and 10°C approximately circulates. The fabric (4) passes through this two cylinders of the stage (26) and moves towards the brushing battery (27),

Said brushing battery (27) consists of a series of brushes applied over the flocked fabric surface, there being shaking bars arranged on the back. Next to each brush, there is an aspirator.

In the last stage of the machine production line; there is a double fabric (4) roller (28) with cutting.

The bottom-coating, background colour and/or pore closing applying device (5) has means for the application thereof and for indistinct use composed of a pitched knife (6), a second pitched knife (7) touching the fabric surface and a rotary goffering cylinder (8).

The rotary cylinders (8, 15 and 16) for paste product dispensing, consists of a cylinder engraved on the contour, by several minute holes defining the design to be applied. Said cylinder has in its interior, a longitudinal pressure pitched knife forcing the paste against the cylinder holes next to the area tangential to the fabric (4) . Moreover, the cylinder has inside an electronic pressure probe connected to the external paste feed pump. The cylinder has on its shaft, an independent motor with variable speed and programmable with an angular setting memory synchronised with the other mechanical components of the machine.

The flock dispenser (20) consists of an upper hopper (33) containing flock with a pair of dispensing cylinders (34) rotary to a flock distribution blade (30) to a fabric sieve (32). Beneath the fabric sieve (32), there is an electrostatic grid (29), arranged at a negligible height with respect to the lower circulating fabric (4) .