Method and apparatus for wet processing of fabric

Apparatus for wet processing fabric with fluid, which includes a primary container for containing and processing fabric, mechanism for partially flooding the primary container, and a counterflow recycling mechanism. The primary container includes a kier for wet processing fabric, a chamber disposed within the kier, for receiving fabric and fluid therein, the chamber having a plurality of perforation, wherein the mechanism for partially flooding the primary container includes a receptacle, disposed within the kier beneath the chamber, being positioned to collect fluid which passes through the perforations of the chamber. The receptacle is sized to surround the chamber so that the amount of fluid in the chamber is sufficient to permit the flow of fabric through the chamber and the amount of fluid in the kier outside the receptacle is sufficient to meet net pressure suction heat requirements of the pumping system employed by the apparatus. The counterflow recycling mechanism includes a plurality of ancillary containers for containing fluid and a mechanism for transferring fluid back and forth between the primary container and the ancillary containers. A method for wet processing fabric with fluid is also disclosed.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to wet processing of fabrics, and more 
particularly, to a method and apparatus for wet processing of fabric, such 
as bleaching, dyeing, and washing, which includes partial flooding and 
counterflow recycling. 
2. Description of Related Art 
Wet processing of fabric, such as bleaching, dyeing and washing, is 
typically accomplished either by a continuous process or by a batch 
process. Continuous processing normally includes a counterflow rinsing 
principle wherein fabric continuously moves through different chambers and 
rinse water simultaneously moves through the same chambers in the opposite 
direction of the fabric flow. Rolls positioned between each chamber 
ordinarily squeeze dry the fabric between chambers. Batch processing 
normally involves draining a bleaching batch, refilling the machine with 
rinse water, heating the rinse water to a certain temperature, and 
draining the rinse water, commonly referred to as a "fill and drain" 
process. The fill and drain process can be repeated several times at 
different rinsing temperatures. An alternative batch processing method, 
referred to as an "overflow rinse" process, involves continuously feeding 
fresh water, at a certain temperature, into a bleaching and dyeing chamber 
and continuously draining rinse water through an overflow pipe for a 
specified period of time. 
In a jet or overflow dyeing machine, the ratio of the amount of liquor, or 
rinsing water, to the amount of fabric, or goods, is defined as the 
"liquor ratio". The liquor ratio can be lowered by increasing the amount 
of goods in the chamber and decreasing the liquor level in the jet or 
overflow dyeing machine. In a conventional chamber, lowering the liquor 
ratio can result in "crushing" or surface distortion of the fabric due to 
increased material load in the chamber. Poor fabric flow through the 
chamber may also occur as a result of the fabric laying too dry in the 
chamber at a low liquor level. 
Continuous processing is disadvantageous due to the large volume of water 
which must be pumped through the system in order to provide for effective 
rinsing. For example, 4-10 gallons of water per pound of dry fabric is 
typically required for fabric which is 100% cotton. In addition, the 
quality of the fabric may be compromised in continuous processing due to 
the use of squeeze rolls between the chambers. 
Batch processing also suffers from the disadvantage of requiring a large 
volume of water through the system. Batch processing also involves heating 
the water, thereby requiring the expenditure of energy. Of course, as more 
water is required to be heated, more energy is required to be expended. 
Applicant is aware of the following U.S. patents concerning washing and/or 
dyeing methods and devices. 
__________________________________________________________________________ 
U.S. Pat. No. 
EXPIRES 
INVENTOR 
TITLE 
__________________________________________________________________________ 
2,588,774 
03-11-1969 
Smith AUTOMATIC WASHING 
MACHINE 
3,170,314 
02-23-1982 
Worst WASHING SYSTEM FOR 
ECONOMIZING ON WATER 
USAGE 
3,686,762 
08-29-1989 
Glaze METHOD OF SHRINKING 
AND/OR DYEING KNIT 
GARMENTS 
3,841,116 
10-15-1991 
Klein MULTIPLE AUTOMATIC 
WASHER SYSTEM 
3,932,127 
01-13-1993 
D'Albignac 
DYEING TEXTILE 
MATERIALS OF A BASIC 
CHARACTER 
4,152,113 
05-01-1996 
Walker SYSTEM FOR DYEING 
HOSIERY GOODS 
4,020,658 
05-03-1994 
Thies APATUS FOR WET- 
TREATING FABRICS 
4,080,166 
03-21-1995 
Muller EMULSIFIERS FOR DYEING 
ACCELERATORS BASED ON 
ALKYNAPHHALENES 
4,483,032 
11-20-2001 
Christ PROCESS FOR TREATING 
TEXTILE MATERIAL IN 
JET DYEING MACHINES 
__________________________________________________________________________ 
Walker discloses the saving and re-use of the liquids in a dyeing system, 
thereby avoiding direct dumping into municipal sewers. The dye bath, rinse 
waste water, and finish waste water are moved from tank to tank, heated or 
clarified as necessary, and reused in the dyeing process. 
In Glaze, a dye solution is recirculated to a reservoir. A means of 
transferring the material to be dyed is also shown. D'Albignac pertains to 
recycling, generally, in dyeing processes. 
The remaining patents relate to washing machines. In Smith, the rinse water 
is recirculated and/or added to the suds in the machine. Worst uses the 
same water for rinsing and washing, and in Klein the wash and rinse 
liquids are recirculated among and between the plural washing machines. 
None of the related art appear to disclose the structure, operation, and 
result of the present invented apparatus, or the process of the invented 
method. 
SUMMARY OF THE INVENTION 
The apparatus for wet processing fabric includes a primary container for 
containing and processing fabric, a mechanism for partially flooding the 
primary container, and a counterflow recycling mechanism. The primary 
container includes a kier for wet processing fabric. A chamber is disposed 
within the kier and receives fabric and fluid therein. The chamber has a 
plurality of perforations. The mechanism for partially flooding the 
primary container includes a receptacle, disposed within the kier beneath 
the chamber, which is positioned to collect fluid which passes through the 
perforations of the chamber. The receptacle is sized to surround the 
chamber so that the amount of fluid in the chamber is sufficient to permit 
the flow of fabric through the chamber and the amount of fluid in the kier 
outside the receptacle is sufficient to meet net pressure suction head 
requirements of the pumping system employed by the apparatus. The 
counterflow recycling mechanism includes a plurality of ancillary 
containers for containing fluid and a mechanism for transferring fluid 
back and forth between the primary container and the ancillary containers. 
The method for wet processing fabric includes providing a primary container 
and a plurality of ancillary containers. Each ancillary container is 
initially filled with fluid. Fluid is transferred from one of the 
ancillary containers to the primary container and fabric is concurrently 
circulated within the primary container. The fabric is then bleached in 
the primary container and the primary container is thereafter drained. For 
each of the remaining ancillary containers, fluid is transferred from one 
of the ancillary containers to the primary container, the fabric is either 
rinsed or neutralized using the partial flooding mechanism, and the fluid 
thereafter transferred from the primary container to one of the ancillary 
containers which contains no fluid. As a final rinse, the primary 
container is filled with fluid and the fabric is rinsed in the primary 
container. The fluid is then transferred from the primary container to one 
of the ancillary containers which contains no fluid. Finally, the fabric 
is unloaded from the primary container. 
OBJECTS OF THE INVENTION 
The principal object of the invention is to provide a method and apparatus 
for bleaching and dyeing fabric which minimizes water consumption. 
A further object of this invention to provide a method and apparatus for 
bleaching and dyeing fabric which minimizes adverse effects on fabric 
quality. 
A further object of this invention to provide a method and apparatus for 
bleaching and dyeing fabric which reduces energy consumption. 
Another object of this invention to provide a method and apparatus for 
bleaching and dyeing fabric which will result in faster bleaching and 
dyeing processing. 
A further object of this invention to provide a method and apparatus for 
bleaching and dyeing fabric which reduces the amount of manual labor 
heretofore required in connection with bleaching and dyeing.

DETAILED DESCRIPTION 
Referring now to the drawings, and particularly to FIG. 1, the invented 
apparatus 10 for bleaching and dyeing fabric 11 is diagrammatically shown. 
Preferably the entire apparatus 10 is controlled by a programmable 
controller 13, which controls the opening and closing of valves, the 
operation of subsystems, and the timing of operations. As used herein, the 
term "programmable controller" means an electric or electronic device 
(e.g., a computer) for governing in some programmable and predetermined 
way the power delivered to an ancillary device. The apparatus 10 is 
powered by electric power from power source 15. 
Fluid 12 is preferably supplied through a conduit 14 from two fluid sources 
16, 18, controlled by fluid valves 20, 22, respectively, although a single 
fluid source may also be employed. The two fluid sources 16, 18 typically 
supply hot and cold water, respectively, or treated and untreated water, 
respectively. Fluid 12 from the two sources 16, 18 is combined through a 
blend fill 24, which is preferably a three-way pneumatically controlled 
valve. The blend fill 24 blends hot and cold water to a desired 
temperature from fluid sources 16 and 18. If the two fluid sources 16, 18 
supply treated and untreated water, the blend fill 24 operates merely to 
select between the two sources. A flowmeter 26 controls the volume of 
fluid 12 supplied to the system. A pneumatically controlled fill valve 28 
regulates the flow of fluid 12 into the system. A check valve 30 is 
positioned on the conduit 14 between the fill valve 28 and the kier 51. 
Fluid 12 is thereafter pumped through the system by a main pump 32. Fluid 
12 is routed to a counterflow recycling system 34, to an additions system 
36, or to a temperature control system 38, as required. 
Fluid 12 routed through the temperature control system 38 first passes 
through an adjustable nozzle pressure control valve 40. Lint is then 
removed from the fluid 12 with a lint filter 42. The temperature of the 
fluid 12 is controlled by passing the fluid 12 through a heating element 
44, controlled by a modulating heating valve 46, and through a cooling 
element 48, controlled by a modulating cooling valve 50. The temperature 
controlled fluid is then directed into a primary container which includes 
a chamber 52 contained within a kier 51. Preferably, the chamber 52 
includes perforations 52a. The chamber, 52 is supported within the kier 51 
by support mechanisms 53. Each support mechanism 53 includes a lower 
member 53a affixed to the interior wall of the kier 51, at approximately 
the horizontal centerline of the kier, and an upper member 53b which 
extends from the outer rounded wall of the chamber 52. An upper member 53b 
is adapted to rest on a lower member 53a, thus suspending the chamber 52 
within the kier 51. Typically, upper and lower members are welded to one 
another. Fabric 11 is loaded into and unloaded from the chamber 52 by 
fabric supplying means 54 which includes main winch 56, a fabric running 
control device 58, a quick change venturi system 60, a plaiting system 62, 
and an unloading winch 64. Main winch 56 pulls the fabric 11 from a bin 
and into contact with fabric running control device 58 which feeds the 
fabric 11 into the quick change venturi system 60. Fluid 12 and fabric 11 
are combined within the venturi system 60 and plaited into the chamber 52 
by the plaiting system 62. The fluid content of the kier 51 is initially 
monitored by a level indicator 66 connected to the kier 51. The kier 51 
includes means 68 for draining fluid from the kier. A pneumatically 
controlled overflow rinse valve 70 communicates with draining means 68. 
Means for recirculating fluid through the primary container includes a 
primary drain 69, located a the base of the kier 51, which is connected to 
conduit 14, and which serves as a transfer point for fluid 12 into and out 
of the kier 51, as regulated by transfer valve 71. 
The kier 51 also contains means 72 for partially flooding the chamber. 
Partial flooding means 72 encapsulates the chamber 52. Partial flooding 
means 72 includes a receptacle 74 having a top opening 74a which includes 
a rim 74b. The receptacle 74 ensures that the fluid level inside the 
chamber 52 is high enough to avoid crushing and to provide for good fabric 
flow through the chamber 52, but allows the fluid level outside the 
receptacle 74 to drop to the minimum level for the net pressure suction 
head requirements of main pump 32. Processing fluid inside the chamber 52 
exits through the perforations 52a of the chamber 52 into partial flooding 
means 72. Upon filling, the fluid flows over the top rim 74b of the 
receptacle 74 and cascades down to the kier fluid level outside the 
chamber 52, which leads to a substantial improvement of the overflow rinse 
process, because rinse fluid exiting the chamber will not come again in 
contact with the fabric and because of the continuous skimming effect 
which occurs at the top rim 74b of the receptacle 74. Partial flooding 
means 72 includes a drain valve 76 mounted on the bottom of the receptacle 
74 in order to allow for draining and filling of the kier 51. 
In the preferred embodiment, only the side walls 52b and the rounded 
interior chamber wall of the chamber 52 include perforations 52a. The 
rounded exterior chamber wall 52c is not perforated. In this preferred 
embodiment, partial flooding means 72 includes two generally semi-circular 
shaped stainless steel panels 106a, 106b which are mounted on the side 
walls 52b of the chamber 52, parallel to the side walls 52b of the chamber 
52, at the bottom portion of the chamber 52. A panel 106 is mounted on a 
side wall 52b with a connector strip 108 which creates a space separating 
the panel 106 from the side wall 52a. Thus, two receptacles 74a, 74b are 
created whereby fluid 12 escaping from within the chamber 52 through the 
chamber perforations 52a is collected within the receptacles. Spacers 110 
may also be positioned between the panel 106 and the side wall 52a to 
maintain the space between the two during fabric processing. In addition 
to the two receptacles 74a, 74b which are mounted to the side walls 52a of 
the chamber 52, a drain compartment 112 is also provided which connects 
one side receptacle to the other. The drain compartment 112 includes a 
pan-like stainless steel member 114 which mounts on the bottom of the 
chamber 52 and is affixed to and disposed beneath both side wall 
receptacles 74a, 74b. Thus, the drain compartment 112 defines a channel 
between, and serves as a common fluid collection point for, both side 
receptacles 74a, 74b. Drain valve 76 communicates with a hole within the 
drain compartment 112 and permits fluid to be drained from partial 
flooding means 72 into the kier 51. Typically, the panels 106a, 106b, 
connector strip 108, and pan-like member 114 are welded to the chamber 52. 
Fluid 12 routed to the additions system 36 is added to an additional vessel 
78, through a pre-additions pneumatic safety interlocking valve 80 and 
pre-additions manual valve 82. Selected additives are combined with the 
fluid. The required additives are transported to the vessel 78 from a drug 
room. The additional vessel 78 includes a manual drain valve 86 for 
draining the contents thereof as required. The combined fluid and 
additives are pumped back into the main system at point X along the 
conduit 14 by an additions pump 88, as regulated by a post-additions 
manual valve 90, a post-additions pneumatically controlled valve 92, and a 
post-additions check valve 94. 
Fluid 12 routed to the counterflow recycling system 34 is directed to a 
plurality of ancillary containers 96, as regulated by a pneumatically 
controlled recycling valve 98. Each ancillary container 96 is provided 
with a pneumatically controlled inlet valve 100 for regulating the flow of 
fluid into the ancillary container, a manual drain valve 102 for 
regulating drainage from the ancillary container, and a pneumatically 
controlled outlet valve 104 for redirecting the contents of the ancillary 
container back into the main system. The contents of the ancillary 
containers are redirected back into the main system at point Y. 
In operation, and assuming that the kier 51 and each of the ancillary 
containers 96 is empty, each ancillary container 96 is first filled with 
fluid 12, which is preferably clean water. Although the ancillary 
containers 96 may be filled directly from the fluid sources 16, 18, it is 
more typical to first fill the kier 51 and then transfer the fluid 12 from 
the kier 51 to an ancillary container 96, which results in less 
complicated programming requirements. 
The basic steps involved in the invented process 200 include bleaching the 
fabric (step 202), neutralizing the fabric (step 204), and rinsing the 
fabric (steps 206a, 206b). The sequence and number of steps will vary 
according to the type of fabric 11, the number of ancillary containers 96 
employed, and the preferences of the user. The process 200 will be 
explained by using an example in which three ancillary containers 96 are 
employed. 
After filling each ancillary container 96 with clean water, the process 200 
begins with a bleaching phase 202. The bleaching phase 202 includes 
transferring the fluid content of one of the ancillary containers 96 to 
the chamber 52, bleaching the fabric 11 in the chamber 52, and draining 
the fluid content from the chamber 52. In the example, the fluid content 
of ancillary container 96a is transferred to chamber 52 by opening 
pneumatically controlled outlet valve 104a and pumping the fluid content 
through conduit 14 and temperature control system 38 into the chamber 52. 
The transfer operation does not ordinarily include any temperature 
control. The objective is simply a rapid transfer. 
Fabric 11 is loaded into the chamber 52 via fabric supplying means 54. 
Chemicals are added to the fluid 12 within the chamber 52 through the 
additions system 36. Various types of chemicals may be employed to bleach 
fabric, and the following references to specific chemicals is intended for 
illustrative purposes only. Typically a three stage additions cycle 
occurs. First, defoamerand wetting agents are introduced into the fluid 12 
by mixing the agents in the additional vessel 78. The contents of the 
additions vessel 78 is then pumped back into the main system at point X by 
the additions pump 88. Second, a caustic agent and a sequestrian (for 
binding with iron) are added to the fluid 12 in order to adjust the pH 
factor and facilitate fiber breakup. The contents of the additions vessel 
78 is then again pumped back into the main system at point X by the 
additions pump 88. Finally, peroxide is added with a stabilizer (for 
stabilizing peroxide) in order to provide the bleaching capability and the 
contents of the additions vessel 78 pumped back into the main system at 
point X by the additions pump 88. The bleaching fluid is circulated 
through the temperature control system 38, heated to a desired 
temperature, and maintained at the desired temperature for a desired 
period of time, thereby bleaching the fabric. Thereafter, the bleaching 
fluid is cooled to a desired temperature and drained from the chamber 52. 
After the bleaching phase 202, the process continues with an initial 
rinsing phase 206a. The initial rinsing phase 206a includes transferring 
the fluid content of one of the ancillary containers 96 to the chamber 52, 
rinsing the fabric 11 in the chamber 52, and transferring the fluid 
content of the chamber 52 to one of the ancillary containers 96. In the 
example, the fluid content of ancillary container 96b is transferred to 
chamber 52 by opening pneumatically controlled outlet valve 104b and 
pumping the fluid content through conduit 14 and temperature control 
system 38 into the chamber 52. The rinsing fluid is circulated through the 
temperature control system 38, heated to a desired temperature, and 
maintained at the desired temperature for a desired period of time, 
thereby rinsing the fabric. The fluid content of chamber is then 
transferred to ancillary container 96a by opening pneumatically controlled 
transfer valve 98 and pumping the fluid content through conduit 14 and 
counterflow recycling system 34 into the ancillary container 96a. 
The process continues with a neutralizing phase 204 after the initial 
rinsing phase 206a. The neutralizing phase 204 includes transferring the 
fluid content of one of the ancillary containers 96 to the chamber 52, 
neutralizing the fabric 11 in the chamber 52, and transferring the fluid 
content of the chamber 52 to one of the ancillary containers 96. In the 
example, the fluid content of ancillary container 96c is transferred to 
chamber 52 by opening pneumatically controlled outlet valve 104c and 
pumping the fluid content through conduit 14 and temperature control 
system 38 into the chamber 52. Acetic acid is added to the additional 
vessel 78 in order to provide the neutralizing capability and the contents 
of the additions vessel 78 pumped back into the main system at point X by 
the additions pump 88. The fluid content of chamber 52 is then transferred 
to ancillary container 96b by opening pneumatically controlled transfer 
valve 98 and pumping the fluid content through conduit 14 and counterflow 
recycling system 34 into the ancillary container 96b. 
A final rinsing phase 206b typically follows the neutralizing phase 204. 
The final rinsing phase 206b includes transferring fluid 12 from one or 
both of the fluid sources 16, 18 to the chamber 52, and rinsing the fabric 
11 in the chamber 52. After the final rinse, the fluid content of chamber 
52 is then transferred to ancillary container 96c by opening pneumatically 
controlled transfer valve 98 and pumping the fluid content through conduit 
14 and counterflow recycling system 34 into the ancillary container 96c. 
Fabric 11 is thereafter unloaded by fabric supplying means 54. Thus, at 
the conclusion of one process cycle, ancillary container 96a contains 
fluid which was used in the initial rinse phase 206a, ancillary container 
96b contains fluid which was used in the neutralizing phase 204, and 
ancillary container 96c contains fluid which was used in the final rinse 
phase 206b. The system is therefore prepared for subsequent process 
cycles. 
The three ancillary container example described above is summarized below 
in table form and includes preferred temperatures and timing 
characteristics. 
______________________________________ 
STEP DESCRIPTION 
______________________________________ 
1 Transfer 96a.fwdarw.chamber 
(160.degree. F.) 
2 Load fabric 
3 Add agents: 
1st: Defoamer, wetting agent 
2nd: Caustic, sequestrian 
3rd: Peroxide, stabilizer 
4 Heat to 210.degree. F. 
5 Hold 30 min. 
6 Cool to 180.degree. F. 
7 Drain 
8 Transfer 96b.fwdarw.chamber (140.degree. F.) 
9 Heat to 170.degree. F. 
10 Hold 5 min (170.degree. F.) 
11 Transfer chamber.fwdarw.96a (170.degree. F.) 
12 Transfer 96c.fwdarw.chamber (92.degree. F.) 
13 Heat to 140.degree. F. 
14 Add Acetic Acid 
15 Hold 5 min. (140.degree. F.) 
16 Transfer chamber.fwdarw.96b (140.degree. F.) 
17 Fill chamber (100.degree. F.) 
18 Hold 5 min. (100.degree. F.) 
19 Check pH and peroxide 
20 Transfer chamber.fwdarw.96c (100.degree. F.) 
21 Unload 
Total specific water usage: 5 l/kg (0.6 gal/lb) 
______________________________________ 
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION 
From the foregoing, it is readily apparent that I have invented an improved 
method and apparatus for bleaching and dyeing, which minimizes adverse 
effects on fabric quality, reduces rinse water and energy consumption, 
increases processing capacity, and reduces the amount of manual labor 
heretofore required. 
It is to be understood that the foregoing description and specific 
embodiments are merely illustrative of the best mode of the invention and 
the principles thereof, and that various modifications and additions may 
be made to the method and apparatus by those skilled in the art, without 
departing from the spirit and scope of this invention, which is therefore 
understood to be limited only by the scope of the appended claims.