Patent Description:
In the textile industry, it is necessary to wash fabrics during the production thereof. Washing can take place in various phases or steps of the production of the fabric, which is normally stored in reel form. Fabrics are usually washed in continuous washing machines or in discontinuous washing machines.

Continuous washing machines normally offer high productivity, but take up a large amount of space since the fabric normally travels through multiple washing tubs arranged in a line, forming what is normally referred to as a washing system.

In contrast with continuous washing machines, discontinuous washing machines are known in which the fabric that is unwound from a first cylinder passes through a vat that comprises a bath for treating the fabric and is wound onto a second cylinder. When the fabric is wound onto the second cylinder, the same operation is performed in the opposite direction, i.e. the fabric is unwound from the second fabric, passed through said treatment bath, and then wound back onto the first cylinder, and this alternating process is repeated until completing the desired treatment. Machines of this type are also known as "jigger" machines.

Discontinuous machines normally offer lower productivity than continuous machines. Nevertheless, they also have advantages since they take up less space and are normally more economical than continuous machines.

The document <CIT> discloses a "jigger" device in which the fabric passes alternately from one cylinder to the other, passing through intermediate vats. The liquid inside said vats is continuously monitored and supplied by pipelines. Both vats are connected though valves and have the thinnest section possible in order to minimize the liquid that they contain. The document also discloses the use of stripping pipes to get rid of any water layer on one of the two surfaces of the fabric.

The document <CIT> discloses a discontinuous machine for offshore wet processing of fabrics. More specifically, this document is cited as it shows in <FIG> a connection system between vats and drains.

One subject of the present invention is that of disclosing a discontinuous machine for treating and/or washing fabrics that has greater productivity than known discontinuous machines and offers greater compactness than known continuous machines. Said greater productivity makes it possible to considerably reduce the operating time of the machine that is the subject of the present invention. Additionally, the machine for treating and/or washing fabrics that is the subject of the present invention reduces the consumption of energy and chemical products necessary for performing a given treatment.

Therefore, the present invention discloses a machine for washing fabrics, which comprises:.

In a preferred embodiment, each vat comprises a particular submerged suction device configured to circulate the bath in a way substantially perpendicular to the fabric.

The submerged suction devices comprised in the vats of the washing module, as well as the dryers arranged between the vats and the cylinders of the modules for collecting and supplying fabric, make it possible to speed up the penetration of the bath into the fabric to be treated. This makes for a more efficient process since by making the bath pass through the fabric to be treated, the washing agents and/or other types of auxiliary products (for example dyes) can penetrate into the fabric more rapidly, thus reducing the process time and reducing the amount of bath required for a given treatment since it is used in a more efficient manner.

Although the penetration of the bath into the fabric is maximised with a machine that comprises a pair of fabric dryers and a submerged suction device, said penetration is also increased with respect to the known prior art in embodiments of the machine that are the subject of the present invention that comprise a submerged suction device and/or a fabric dryer.

The foregoing makes it possible to solve the needs of the most demanding companies that seek to improve a better solution (higher speed), at a better price (reduction of process times, use of chemical products and energy), while also allowing them to offer products with greater value added, produced using the most environmentally friendly processes (reduced use of chemical products and energy).

In one embodiment, the machine that is the subject of the present invention comprises reversible means for controlling the level of the bath in the vats configured for counter-current fabric treatment. In a preferred embodiment, each vat comprises means for controlling the level of the bath, configured so that the level of the bath is lower in the fabric intake vat, and which comprise a drain and a bath fluid inlet in each vat. Preferably, the machine that is the subject of the present invention comprises automatic means for opening and closing said drains. Advantageously, the machine that is the subject of the present invention comprises a fluid connection between vats which rises above said drains.

In one embodiment, the washing module additionally comprises between the first and the second vat a motorised drum configured to guide and convey the fabric from the first vat to the second vat and to minimise the tensions of the fabric. In a preferred embodiment, said drum comprises a plurality of perforations distributed around its entire perimeter.

Advantageously, the machine that is the subject of the present invention comprises at least one sprinkler for each vat, each of which is configured to sprinkle the fabric that passes around the drum. Preferably, each sprinkler is configured to sprinkle the fabric with the bath of its particular vat.

In one embodiment, the machine that is the subject of the present invention comprises a fabric dryer between the first and the second vat. Preferably, the above-mentioned dryers are configured to dry the fabric by suction or vacuum. Alternatively, the above-mentioned dryers are configured to dry the fabric by blowing, mechanical systems (padders etc.), etc..

Advantageously, said winding cylinders are horizontally offset with respect to the vats, i.e. said winding cylinders are not located above the vats.

In one advantageous embodiment, the machine that is the subject of the present invention comprises a spreader device for each winding cylinder configured to remove any wrinkles from the fabric before it is wound onto the corresponding cylinder.

Preferably, each module for collecting and supplying fabric comprises means for wetting the fabric. Advantageously, said means for wetting the fabric are located between the spreader device and the dryer of each cylinder. Preferably, said means for wetting the fabric comprise a sprinkler.

Preferably, the machine that is the subject of the present invention additionally comprises an auxiliary reel holder configured to load and/or unload the fabric from the machine. Said auxiliary reel holder can be complemented with a winding arm. Said winding arm can also replace said auxiliary reel holder.

Advantageously, each vat is provided with a plurality of rollers configured to guide the fabric that circulates through the inside thereof.

Preferably, each vat is provided with a device for stirring the bath contained therein.

Advantageously, the machine that is the subject of the present invention comprises means for heating the bath contained in each vat.

In one embodiment, the machine that is the subject of the present invention comprises a casing configured to house inside of same the components of the above-mentioned device. In a preferred embodiment, said casing is covered, at least partially, with an insulation.

Although the machine that is the subject of the present invention is preferably configured to wash fabric, said machine can also be configured to dye fabric. When the machine is configured to wash fabric, the vats contain, inter alia, detergents, whereas when it is configured to dye fabric, the vats contain, inter alia, dye. In addition to containing detergents or dyes, the vats can also contain other types of products for treating fabric.

In this document the directions horizontal, vertical, up, down, etc. are understood according to the normal working position of the machine for washing fabrics that is the subject of the present invention.

A series of drawings showing one embodiment of a baler according to the present invention are appended to ensure better understanding through explanatory but non-exhaustive examples.

In the figures, features that are the same or equivalent have been identified with the same numbers.

<FIG> show in a front view and schematically an embodiment of a machine for washing fabrics according to the present invention. In the shown embodiment, the machine <NUM> comprises three modules <NUM>, <NUM>, <NUM>. To allow easier appreciation of details which, due to the scale used in <FIG>, may be difficult to appreciate, <FIG> respectively show the modules <NUM>, <NUM> and <NUM> separately.

The embodiment of the machine <NUM> shown in the figures comprises a first module <NUM> for collecting and supplying fabric, a second module <NUM> for washing and a third module <NUM> for collecting and supplying fabric, the second module <NUM> being located between the first module <NUM> and the third module <NUM>.

Optionally, the machine <NUM> can be provided with an auxiliary reel holder <NUM> configured to load and unload the fabric <NUM> from the machine <NUM>, and specifically to load and unload the fabric from the first motorised cylinder <NUM> and/or from the second motorised cylinder <NUM>. The above-mentioned auxiliary reel holder <NUM> may be complemented by or replaced with a winding arm (not shown). Said loading and unloading of the fabric <NUM> can be carried out through the doors <NUM>, <NUM> located on the first and the third module <NUM>, <NUM>, respectively. Preferably, said doors <NUM>, <NUM> are located on the side of the casing <NUM> of their respective modules, although they may also be placed on the front and/or rear of same. A discontinuous line and reference number <NUM> are used to depict the fabric being loaded into or unloaded from the machine <NUM> with the help of the auxiliary reel holder <NUM>. The above-mentioned process for loading and unloading the fabric <NUM> is only carried out at the start of the process (loading the fabric <NUM>) and after the end of same (unloading the fabric <NUM>). When in operation, the fabric <NUM> travels from the first module <NUM> to the third module <NUM>, and vice versa, with no intervention from the above-mentioned auxiliary reel holder <NUM> or from the winding arm, in the case that the machine <NUM> is provided with same.

The casing <NUM> of the machine can be entirely or partially covered with insulation so as to minimise the heat losses of the machine and thus to improve its efficiency. Additionally, said insulation also serves to protect the operators from possible burns in the event of touching the casing. Said insulation is preferably located on the inside of the casing <NUM>.

As can be seen, in this embodiment the motorised cylinders <NUM>, <NUM> for winding fabric are arranged facing one another at opposite ends of the machine. Both cylinders <NUM>, <NUM> can be located at the same height with respect to the ground or base of the machine <NUM>, although they can also be placed at uneven heights.

The machine for washing and/or treating fabrics that is the subject of the present invention has discontinuous operation, in which the fabric is unwound from a first motorised cylinder and is wound onto a second motorised cylinder after passing through a bath for treating said fabric, and vice versa, i.e. once the fabric has been wound onto the second motorised cylinder, the process is reversed and the fabric is unwound from the second cylinder and after passing through the treatment bath is wound onto the first cylinder, repeating this alternating process until completing the desired treatment of the fabric. Machines of this type are known in the textile industry as "jigger" machines.

As can be seen, in the shown embodiment, the two modules <NUM>, <NUM> for collecting and supplying fabric comprise the same components distributed symmetrically with respect to the washing module <NUM>.

<FIG> schematically shows a front view of the first module <NUM> of the embodiment of a machine <NUM> for washing fabrics shown in <FIG>. This figure depicts the fabric <NUM> by a continuous line in the position in which said fabric is unwound from the first motorised cylinder <NUM>. A discontinuous line depicts the position occupied by the fabric <NUM> and the spreader device <NUM> when the fabric <NUM> is completely wound onto the first motorised cylinder <NUM>. Said spreader device <NUM> can be formed by rocker-type curved bars and is configured to remove any wrinkles from the fabric <NUM> before it passes onto the cylinder <NUM>. Although it has obvious advantages, the use of the spreader device <NUM> in the machine <NUM> of the present invention is optional.

After passing through the vat <NUM> (see <FIG>) the fabric <NUM> passes through a fabric dryer <NUM>. In the shown embodiment, said fabric dryer <NUM> is a vacuum tube and serves to extract the moisture from the fabric <NUM>, and specifically the moisture not fixed to the fibre that is located between the gaps between the weft and the warp. Although the dryer <NUM> is preferably a vacuum tube, it can also be in the form of squeezing rollers (padders), air-blowing systems, etc..

The first module <NUM> of the shown embodiment also comprises means for wetting the fabric <NUM>, and specifically comprises a sprinkler <NUM>, between the dryer <NUM> and the spreader device <NUM>. In other embodiments, said sprinkler <NUM> can have a different location within the first module <NUM>. The purpose of the sprinkler <NUM> is to wet the fabric <NUM> when it is unwound from the cylinder <NUM>. Although its use is advantageous and recommendable, said sprinkler <NUM> is an optional feature of the machine <NUM>. Generally the working liquid of the sprinkler <NUM> is water, although it can also operate with other liquids, for example chemical products for treating the fabric.

This figure also shows the means <NUM> for feeding and guiding the fabric <NUM> of the first module <NUM>, which in the shown embodiment are rollers.

<FIG> schematically shows a front view of the second module <NUM> of the embodiment of a machine <NUM> for washing fabrics shown in <FIG>. Said second module <NUM> is the module for washing or treating the fabric <NUM>. Said washing module <NUM> comprises two vats <NUM>, <NUM>' which contain a bath <NUM>, <NUM>' for treating or washing the fabric <NUM>.

Although the machine <NUM> that is the subject of the present invention preferably has two vats, it is possible for other embodiments to have more than two vats or simply one. The fact of having two vats <NUM>, <NUM>' makes it possible to perform counter-current washing of the fabric <NUM>, counter-current washing being understood to be the fact that, for example, when the fabric travels towards the second cylinder <NUM>, i.e. it is unwound from the first cylinder <NUM> and is wound onto the second cylinder <NUM>, the bath of the first vat <NUM> is dirtier than that of the second vat <NUM>'. As can be seen, in the shown embodiment the bath <NUM>, <NUM>' of each vat <NUM>, <NUM>' is at a different level. For this purpose, the second module <NUM> comprises means for controlling the level of the bath <NUM>, <NUM>' in each vat <NUM>, <NUM>'. Said means for controlling the level of the bath <NUM>, <NUM>' comprise, in this embodiment, a drain <NUM>, <NUM>' and a bath fluid inlet (not shown) in each vat <NUM>, <NUM>'. The machine <NUM> can comprise automatic means for opening and closing said drains <NUM>, <NUM>', which in the shown embodiment are gates <NUM>, <NUM>', although they can also be valves, etc. The shown embodiment additionally comprises a fluid connection between vats that rises above the drains <NUM>, <NUM>'. In this embodiment, said fluid connection comprises a projection <NUM> with a triangular section, although it may adopt other shapes.

The above-mentioned means for controlling the level of the bath <NUM>, <NUM>' are configured so that the level of the bath <NUM>, <NUM>' is lower in the vat <NUM>, <NUM>' that intakes the fabric <NUM>. Since the operating cycles of the machine are alternating (the fabric <NUM> is unwound from the cylinder <NUM> and, after passing through the bath <NUM>, <NUM>', is wound onto the cylinder <NUM>, and vice versa), said control means can be reversible in order to allow the fabric <NUM> to undergo counter-current treatment independently of the cylinder <NUM>, <NUM> onto which it is being wound/unwound.

In the case of <FIG> and <FIG>, they show the end of a work cycle of the machine in which the fabric has been unwound from the motorised cylinder <NUM>, has entered the bath <NUM> of the vat <NUM>, so that, after passing over the perforated drum <NUM>, it is inserted into the bath <NUM>' of the vat <NUM>' and then wound onto the motorised cylinder <NUM>. Therefore, in said figures the level of the bath <NUM>' is higher than that of the bath <NUM>. This is because the gate <NUM>' of the drain <NUM>' is closed and the bath fluid supply means are supplying fluid to the vat <NUM>' (not shown). When the level of the bath <NUM>' reaches the upper end of the projection <NUM>, the bath <NUM>' overflows into the vat <NUM>, from where it is directed towards the drain <NUM> since the gate <NUM> is open. When the operating cycle of the machine is reversed, i.e. the fabric is unwound from the motorised cylinder <NUM> and wound onto the motorised cylinder <NUM>, the means for controlling the level of the bath also reverse their operation, and the level of the bath <NUM> becomes higher than that of the bath <NUM>'.

To maximise the effect of the bath <NUM>, <NUM>' each vat <NUM>, <NUM>' comprises a submerged suction device <NUM>, <NUM>'. Each submerged suction device <NUM>, <NUM>' is configured to force the circulation of the bath <NUM>, <NUM>' through the fabric <NUM>, thus increasing the effect of said bath <NUM>, <NUM>'. Said circulation of the bath <NUM>, <NUM>' through the fabric <NUM> is carried out, preferably, in a substantially perpendicular manner. Said submerged suction devices <NUM>, <NUM>' can be used to sprinkle the fabric <NUM> that passes over the drum <NUM>, thus maximising the use of the bath <NUM>, <NUM>' and increasing the efficiency of the machine <NUM>. For this purpose, the bath <NUM>, <NUM>' collected by the submerged suction devices <NUM>, <NUM>' is fed by means of a particular pump <NUM>, <NUM>' towards sprinklers <NUM>, <NUM>' that can be located above the drum <NUM>. Said drum <NUM> can be perforated in order to maximise its mechanical washing effect. Said mechanical washing effect of the drum <NUM> can be increased with the use of the sprinklers <NUM>, <NUM>'. In addition to increasing the washing of the fabric <NUM>, the drum <NUM> can also be configured to reduce the tensions of the fabric <NUM> while it passes from one vat to another. Although its use has numerous advantages, it is possible to replace the drum <NUM> with a drying device similar to those present in the first module <NUM> and the third module <NUM>. In the embodiments that are provided with same, said drying device is located between the vats <NUM>, <NUM>'. Certain embodiments of machines for washing fabric according to the present invention may also lack a drum <NUM> and a drying device replacing same.

Although they are not shown in <FIG>, the vats <NUM>, <NUM>' can comprise stirring means and means for heating the bath <NUM>, <NUM>' contained therein, to promote the penetration of the bath <NUM>, <NUM>' into the fabric <NUM>.

In an equivalent manner to the first module <NUM>, the second module <NUM> or washing module can comprise means <NUM>, <NUM>' for feeding and guiding the fabric <NUM>. Said feeding and guiding means <NUM>, <NUM>' of the second module <NUM> can be complemented with submerged means <NUM>, <NUM>' for feeding and guiding the fabric <NUM> in each vat <NUM>, <NUM>'. In the shown embodiment, the feeding and guiding means <NUM>, <NUM>' and the submerged means <NUM>, <NUM>' for feeding and guiding the fabric <NUM> are rollers.

<FIG> schematically shows a front view of the third module <NUM> of the embodiment of a machine <NUM> for washing fabrics shown in <FIG>. In contrast with the first module shown in <FIG> and <FIG>, in the module <NUM> shown in <FIG> the fabric <NUM> is wound, almost completely, onto the second motorised cylinder <NUM>, thus making it possible to observe the position that the spreader device <NUM> adopts when the fabric <NUM> is wound onto the motorised cylinder <NUM>. Note that this is the opposite configuration to that of the first module shown in <FIG> and <FIG>. However, as explained above, the fabric <NUM> is wound onto and unwound from the motorised cylinders <NUM>, <NUM> in an alternating manner until the desired treatment for said fabric is completed.

The third module <NUM> comprises a fabric dryer <NUM> in order to extract moisture from the fabric <NUM>, and specifically to extract the moisture not fixed to the fibre that is located between the gaps between the weft and the warp. Although in the shown embodiment the fabric dryer <NUM> is a vacuum tube, in other embodiments it can be a system of squeezing rollers (padders), an air-blowing system, etc..

In addition to the above-mentioned components, said third module <NUM> can also comprise means <NUM> for feeding and guiding the fabric <NUM> and a sprinkler <NUM> for wetting the fabric <NUM> when it is unwound from the second motorised cylinder <NUM>.

The operation of the third module <NUM> is similar to that of the first module <NUM> described beforehand, although, as mentioned above, the operating cycles of the first and the third module <NUM>, <NUM> are alternating.

In the embodiment shown in <FIG>, the sprinklers <NUM>, <NUM> (see <FIG> and <FIG>) are configured so that when the fabric <NUM> is unwound from the first motorised cylinder <NUM>, the sprinkler <NUM> wets said fabric <NUM> before being inserted into the vats <NUM>, <NUM>' with their respective baths <NUM>, <NUM>' (see <FIG>). After passing through the vats <NUM>, <NUM>' and their respective baths <NUM>, <NUM>', and before it is wound onto the second motorised cylinder <NUM> after passing through the spreader device <NUM>, the dryer dries the fabric <NUM> as described above, without the sprinkler <NUM> coming into operation. Said sprinkler <NUM> comes into operation when the work cycle is reversed and the fabric <NUM> is unwound from the second cylinder <NUM> and wound onto the first cylinder <NUM>.

In the embodiment shown in <FIG> the bath <NUM>, <NUM>' contains detergents since in the shown embodiment the machine <NUM> is configured to wash the fabric <NUM>. However, in other embodiments the bath <NUM>, <NUM>' can contain dye or other chemical products so that the machine dyes or impregnates the fabric <NUM>.

Claim 1:
A machine (<NUM>) for washing fabrics, which comprises:
- a first module (<NUM>) for collecting and supplying fabric (<NUM>) with a first motorised cylinder (<NUM>) for winding fabric (<NUM>),
- a second washing module (<NUM>) which comprises a first and a second vat (<NUM>, <NUM>') for holding a bath (<NUM>, <NUM>') for treating the fabric (<NUM>),
- a third module (<NUM>) for collecting and supplying fabric (<NUM>) with a second motorised cylinder (<NUM>) for winding the fabric (<NUM>),
and means (<NUM>) for feeding and guiding the fabric (<NUM>) configured so that the fabric (<NUM>) travels from the first module (<NUM>) to the third module (<NUM>) passing through the first and the second vat (<NUM>, <NUM>') of the washing module (<NUM>), and vice versa
characterised in that it comprises a first and a second fabric dryer (<NUM>, <NUM>), configured to extract moisture from the fabric (<NUM>), and specifically to extract the moisture not fixed to the fibers that is located between the gaps between the weft and the warp, being a vacuum tube, a system of squeezing rollers (padders) or an air-blowing system, arranged between the first motorised cylinder (<NUM>) and the first vat (<NUM>) and between the second vat (<NUM>') and the second motorised cylinder (<NUM>), respectively.