WO2022169429A1 - Innovation in vacuum leather processing machine and method - Google Patents
Innovation in vacuum leather processing machine and method Download PDFInfo
- Publication number
- WO2022169429A1 WO2022169429A1 PCT/TR2021/050108 TR2021050108W WO2022169429A1 WO 2022169429 A1 WO2022169429 A1 WO 2022169429A1 TR 2021050108 W TR2021050108 W TR 2021050108W WO 2022169429 A1 WO2022169429 A1 WO 2022169429A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- drum
- leather
- blower
- water
- booster
- Prior art date
Links
- 239000010985 leather Substances 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000012545 processing Methods 0.000 title abstract description 21
- 239000002699 waste material Substances 0.000 claims abstract description 11
- 239000004753 textile Substances 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 40
- 239000000126 substance Substances 0.000 claims description 31
- 230000008569 process Effects 0.000 claims description 21
- 238000001816 cooling Methods 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 14
- 239000002245 particle Substances 0.000 claims description 7
- 238000004064 recycling Methods 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 238000012546 transfer Methods 0.000 claims description 4
- 238000005406 washing Methods 0.000 claims description 4
- 239000007788 liquid Substances 0.000 claims description 3
- -1 polypropylene Polymers 0.000 claims description 3
- 230000009467 reduction Effects 0.000 claims description 3
- 230000007704 transition Effects 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 238000010276 construction Methods 0.000 claims description 2
- 239000007791 liquid phase Substances 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims description 2
- 239000000498 cooling water Substances 0.000 claims 2
- 239000004698 Polyethylene Substances 0.000 claims 1
- 238000009833 condensation Methods 0.000 claims 1
- 230000005494 condensation Effects 0.000 claims 1
- 238000010981 drying operation Methods 0.000 claims 1
- 238000012544 monitoring process Methods 0.000 claims 1
- 229920000573 polyethylene Polymers 0.000 claims 1
- 238000005086 pumping Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 20
- 238000004043 dyeing Methods 0.000 abstract description 6
- 238000005516 engineering process Methods 0.000 abstract description 5
- 238000013461 design Methods 0.000 abstract description 3
- 239000000047 product Substances 0.000 description 27
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 6
- 230000007423 decrease Effects 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 239000000835 fiber Substances 0.000 description 6
- 230000003247 decreasing effect Effects 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 230000036541 health Effects 0.000 description 4
- 238000011161 development Methods 0.000 description 3
- 230000018109 developmental process Effects 0.000 description 3
- 239000012071 phase Substances 0.000 description 3
- 239000002351 wastewater Substances 0.000 description 3
- 102000008186 Collagen Human genes 0.000 description 2
- 108010035532 Collagen Proteins 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000007792 gaseous phase Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 238000005554 pickling Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 230000003134 recirculating effect Effects 0.000 description 2
- 229910000906 Bronze Inorganic materials 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229920001436 collagen Polymers 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000002036 drum drying Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000005183 environmental health Effects 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- OMLKPIIYNUNCMY-UHFFFAOYSA-N formic acid;sulfuric acid Chemical compound OC=O.OS(O)(=O)=O OMLKPIIYNUNCMY-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000005445 natural material Substances 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06G—MECHANICAL OR PRESSURE CLEANING OF CARPETS, RUGS, SACKS, HIDES, OR OTHER SKIN OR TEXTILE ARTICLES OR FABRICS; TURNING INSIDE-OUT FLEXIBLE TUBULAR OR OTHER HOLLOW ARTICLES
- D06G1/00—Beating, brushing, or otherwise mechanically cleaning or pressure cleaning carpets, rugs, sacks, hides, or other skin or textile articles or fabrics
- D06G1/005—Beating, brushing, or otherwise mechanically cleaning or pressure cleaning carpets, rugs, sacks, hides, or other skin or textile articles or fabrics inside a rotary receptacle
-
- C—CHEMISTRY; METALLURGY
- C14—SKINS; HIDES; PELTS; LEATHER
- C14C—CHEMICAL TREATMENT OF HIDES, SKINS OR LEATHER, e.g. TANNING, IMPREGNATING, FINISHING; APPARATUS THEREFOR; COMPOSITIONS FOR TANNING
- C14C15/00—Apparatus for chemical treatment or washing of hides, skins, or leather
Definitions
- Subject of the invention is related to design and production of a vacuum leather processing system to be developed with the intention to provide a sustainable and environmentally-friendly production technology for textile products, particularly for leather production.
- the invention is particularly related to developing tanning and dyeing methods which are higher in consumption, shorter timed, more reactive, with a lesser waste volume and pollution load.
- leather is a very special product which is sought for its high durability and performance properties, suitable for use in many different fields, having sustainability properties and being a modification of a natural byproduct.
- adaptation of environmentally-friendly techniques, products and technologies as well as integration of developments in chemical technologies into leather product carry great imporantance to ensure production lives on to future generations in the leather industry which is known by the environmental pollution it causes and which faces an intensive agenda filled with problems related to compliance with ecological criteria.
- Manufactured leather is a product made for spoilable raw leather and hides by processing them from natural fibres into spoil-resistant materials, providing a material suitable for making various goods and tools making human life easier.
- the properties provided by the natural fibre network and tanning processes against environmental and mechanical effects make this product a preferred choice providing long-term user satisfaction in many fields.
- Today, manufactured leather products are deemed as important luxury goods in many industries including automotive and internal decoration which have a large demand for high standard goods, and it is known the market demand for such products grow day by day. No matter what the production purpose is, the principle of "safe product and safe environment" has gained importance in regards of both environmental health and human health in leather industry in recent years.
- Current invention is related to vacuum leather processing machines which are designed to eliminate all problems experiened in current state of the art.
- the main purpose of the invention is to apply a certain level of vacuum to leather processing environment in order to increase the mechanical effect to ensure the space between the tight collagen fibres in the three dimensional helical structure of the leather are pulled further apart for better penetration of the applied dyeing and tanning materials into the fibre structure of the leather and being better diffuse into inter-fibre and intra-fibre structure of the leather in a balanced distribution to better bind with the collagen proteins.
- Another purpose of the invention is to provide controlled vacuuming of the ambient air in the processing environment during leather manufacture to provide a low pressure environment to ensure applied chemicals penetrates into the fibre structures quicker in order to decrease processing time.
- Another purpose of the invention is to decrease atmospheric pressure in the processing environment to provide a frictionless environment and the amount of chemicals consumed according to the mechincal effect in order to decrease the amount of water and chemicals consumed in processing.
- 80-100 % water and 8-12 % chrome on basis of leather weight are used to achieve the expected leather properties in conventional leather manufacture, and only 70% of the applied chrome penetrates the leather at best.
- approximately 100 kgs of chrome is used for the 1 tonne of leather and at least 30 kgs of chrome passes to the waste water in the 1 tonne of water used in processing, thus damaging the environment.
- optimisation studies on tanning procedures allow performance of tanning with the least amount of water with a 6-7% chrome solution prepared by using water in an amount just enough to carry the chrome into the leather fibres.
- dyeing process using the least amount of water can also be performed by dissolcing the dye only in enough water to carry the dye into the fibres and by processing at high pH without performing the pickling process using 100% water, 10% salt and 2% formic acid-sulphuric acid combination based on leather weight.
- the leather production processes subject to the invention use supplementary chemicals to ensure high consumption of tanning substance and best penetration of dye substance into the leather fibres in tanning and dyeing phases by leaving a residue containing APEO, etc.
- the reaction environment provided by the invention design allows decreased use and/or elimination of these substances.
- improvement of the reaction environment for leather production provide savings in water, chemicals and supplementary chemicals, leading to a decrease in the waste water amount and pollution load delivered to the waste water treatement facility, providing energy savings and thus decreasing waste treatment costs. Through all these savings it is also intended to decrease total operation costs.
- the manufacturing system to be developed will allow production of leather goods at least equal to those manufactures with conventional systems in regard of properties like softness, flexibility, durability, resistance and fastness.
- vacuum leather processing machine and method subject to the invention should be assessed in light of the images listed below in order to allow a better understanding of the innovations made to achieve the purposes listed above.
- the drum(l), as one of the main components of the vacuum leather processing machine, allows recirculation of a liquid in the system using a drive system which can operate on single or double rollers or bronze beds.
- the main body of the drum(l) can be produced in various sizes, in cylindrical, hexagonal, octagonal or any other geometric shape according to the intended operation type.
- the drum(l) can be installed on top of a concrete base or steel construction pods.
- the drum(l) can be used as a leather tanning machine, leather processing mixer, wet(humid) curing machine, dry curing machine or leather drum drying machine.
- the drum(l) can be made of five different materials, comprised of stainless steel, polypropylene, polyester, wood or polyethlylene.
- Body of the drum(l) circulates external oil or water or mechanically recirculates internal process water through a heater with its double walled structure.
- the leather or textile product intended for convection or modification is placed into the drum(l).
- the product placed in the drum(l) is washed at a temperature level between 25° C to 50° C according to the amount of product or the intended formula.
- the washing time varies according to factors like the type, the size or the colour of the product placed in the drum(l).
- the washing operation makes the product in the drum(l) soften and pulls the fibres of the product apart to a degree.
- the increase in temperature and moisture in the drum(l) achieve in result of washing negatively affects the application of vacuum in the drum(l).
- the moisture is remoevd from the drum(l) through a valve placed in the internal wall of the drum(l) for this purpose.
- an environment convenient for establishing a vacuum is achieved in the drum(l).
- a blower(2) connected to the drum(l) is used to help establish vacuum in the drum(l).
- the blower(2) allow reduction of the internal pressure in the drum(l) to the level of 600 to 750 mmHg. Even when pressure level is reduced with the help of the blower(2) the required level of vacuum cannot be achieve with this alone.
- At least one booster(3) must be connected to the blower(2) in order to reach the desired level of vacuum. With addition of the booster(3) the internal pressure of the drum(l) is moved from 600 to 750 mmHg level to 750 to 900 mmHg.
- a vacuum pump can also be used as an alternative to the booster(3). After application of negative pressure, water and chemical materials are sent into the drum(l).
- the level of moisture and temperature in the drum(l) rises again.
- the moisture and temperature levels in the drum(l) can be monitored by the hygrometer and thermometer connected to the drum(l) and adjsuted accordingly from the control panel.
- the system can measure the temperature and moisture levels in the drum(l) while the drum(l) working during the process and control parameters like process water temperature, chemical material dosaging amounts, water intake amounts and operation time from the control panel.
- the control panel can be in digital or mechanical structure according to preference.
- waste liquids in lesser amounts in comparison to current state of the art are collected in the waste/recycling reservoir(8).
- This drum(l) process is repated for each procedure to be applied on the product as well as according to the formula.
- element used in the process plate exchangers or pipe exchanger can be used, and external heating can be provided thorugh heater fluids using resistance heaters.
- the process water can be connected to a pipe, exchnager or heater tank through a mechanical recirculation system for recirculating heating of the internal process water.
- a forced mechanical circulation system can be installed to pass the process water in the drum(l) through a dobule walled(hot oil or steam heated) pipe to provide mechanical recirculating heating without using any pump.
- Wet curing and dry curing operations can be performed in the vacuum leather processing machine subject to the invention. Connection of a hot air circulation system into the drum(l) is sufficient for enabling such operations.
- This application both decreases consumption rate of the water and chemicals sent into the drum(l) to dye the product in the drum(l) and helps the water and chemicals penetrate into all fibres of the product.
- the decreased amount of water and chemicals consumed in the drum(l) also decreased the amount of waste generated during operation.
- cooling systems are installed on the outer surfaces of the drum(l), the blower(2) and the booster(3).
- This cooling system may have a double walled structure according to preference. The water circulating in the cooling system between the two walls of the drum(l), the blower(2) and the booster(3) starts to heat up during the process. The heated water in the cooling system is first passed through the heat exchanger(4) to lose some of its heat and then transferred to the water reservoir(5).
Abstract
Subject of the invention is related to design and production of a vacuum leather processing system to be developed with the intention to provide a sustainable and environmentally-friendly production technology for textile products, particularly for leather production. The invention is particularly related to developing tanning and dyeing methods which are higher in consumption, shorter timed, more reactive, with a lesser waste volume and pollution load.
Description
INNOVATION IN VACUUM LEATHER PROCESSING MACHINE AND METHOD
Technical Field
Subject of the invention is related to design and production of a vacuum leather processing system to be developed with the intention to provide a sustainable and environmentally-friendly production technology for textile products, particularly for leather production. The invention is particularly related to developing tanning and dyeing methods which are higher in consumption, shorter timed, more reactive, with a lesser waste volume and pollution load.
State of Art
Today, leather is a very special product which is sought for its high durability and performance properties, suitable for use in many different fields, having sustainability properties and being a modification of a natural byproduct. Nevertheless, adaptation of environmentally-friendly techniques, products and technologies as well as integration of developments in chemical technologies into leather product carry great imporantance to ensure production lives on to future generations in the leather industry which is known by the environmental pollution it causes and which faces an intensive agenda filled with problems related to compliance with ecological criteria.
Manufactured leather is a product made for spoilable raw leather and hides by processing them from natural fibres into spoil-resistant materials, providing a material suitable for making various goods and tools making human life easier. The properties provided by the natural fibre network and tanning processes against environmental and mechanical effects make this product a preferred choice providing long-term user satisfaction in many fields. Today, manufactured leather products are deemed as important luxury goods in many industries including automotive and internal decoration which have a large demand for high standard goods, and it is known the market demand for such products grow day by day. No matter what the production purpose is, the principle of "safe product and safe
environment" has gained importance in regards of both environmental health and human health in leather industry in recent years.
In the current state of the art, many natural and synthetic chemicals are used to convert raw leather into manufactured leather in the leather industry. In the 20th century developments in chemical and mechanical industries have expanded the product and production range used in leather manufacture and leather products better satisfying consumer expectation were offered thanks to many properties infused to the products by use of chemicals. Passing through multiple phases in production to provide the expected properties, the leath products are processed by certain amounts of chemicals in each phase. Thanks to tehcnological developments leather products with various enhanced properties like durability, water-repelling, fire-resistance and many other properties are offered to the market. Alongside all these positive effects, chemical products also cause new problems every passing day. Some of the new products which keep appearing and their pollutants have marked negative effects on human health and environment. The hazard posed by chemical materials materialise as damage to human health and environment during their production or use or when they turn into waste. Regulations and restrictions on toxic and dangerous properties of chemicals are implemented to provide protection against their negative effects on human health and environment. In recent years awareness on restricted substances have become more and more imporant in the leather industry.
In conclusion, conduct of serious studies on new, environmentally-friendly, high consumption production systems for the leather industry and comparative analyses on leather products manufactured with such systems have become a necessity.
Purpose of the Invention
Current invention is related to vacuum leather processing machines which are designed to eliminate all problems experiened in current state of the art.
The main purpose of the invention is to apply a certain level of vacuum to leather processing environment in order to increase the mechanical effect to ensure the space between the tight collagen fibres in the three dimensional helical structure of the leather are pulled further apart for better penetration of the applied dyeing
and tanning materials into the fibre structure of the leather and being better diffuse into inter-fibre and intra-fibre structure of the leather in a balanced distribution to better bind with the collagen proteins.
Another purpose of the invention is to provide controlled vacuuming of the ambient air in the processing environment during leather manufacture to provide a low pressure environment to ensure applied chemicals penetrates into the fibre structures quicker in order to decrease processing time.
Another purpose of the invention is to decrease atmospheric pressure in the processing environment to provide a frictionless environment and the amount of chemicals consumed according to the mechincal effect in order to decrease the amount of water and chemicals consumed in processing. For example, 80-100 % water and 8-12 % chrome on basis of leather weight are used to achieve the expected leather properties in conventional leather manufacture, and only 70% of the applied chrome penetrates the leather at best. Following an example of 1 tonne of leather material, approximately 100 kgs of chrome is used for the 1 tonne of leather and at least 30 kgs of chrome passes to the waste water in the 1 tonne of water used in processing, thus damaging the environment. Furthermore, optimisation studies on tanning procedures allow performance of tanning with the least amount of water with a 6-7% chrome solution prepared by using water in an amount just enough to carry the chrome into the leather fibres. In addition, dyeing process using the least amount of water can also be performed by dissolcing the dye only in enough water to carry the dye into the fibres and by processing at high pH without performing the pickling process using 100% water, 10% salt and 2% formic acid-sulphuric acid combination based on leather weight.
The leather production processes subject to the invention use supplementary chemicals to ensure high consumption of tanning substance and best penetration of dye substance into the leather fibres in tanning and dyeing phases by leaving a residue containing APEO, etc. The reaction environment provided by the invention design allows decreased use and/or elimination of these substances. In addition, improvement of the reaction environment for leather production provide savings in water, chemicals and supplementary chemicals, leading to a decrease in the waste water amount and pollution load delivered to the waste water treatement facility, providing energy savings and thus decreasing waste treatment costs. Through all these savings it is also intended to decrease total operation costs.
The manufacturing system to be developed will allow production of leather goods at least equal to those manufactures with conventional systems in regard of properties like softness, flexibility, durability, resistance and fastness.
Converting leather, a natural material, into durable, resistant and high performance luxury goods required by various sectors at industrial volumes using clean technologies will establish the infrastructure for sustainable production in leather industry.
Detailed Description of the Invention
The vacuum leather processing machine and method subject to the invention should be assessed in light of the images listed below in order to allow a better understanding of the innovations made to achieve the purposes listed above.
These images include;
Image - 1 Circuit diagram view of the vacuum leather processing machine subject to the invention.
Numbers are indicated on the image in order to allow a better understanding of the vacuum leather processing machine subject to the invention. These include;
1. Drum
2. Blower
3. Booster
4. Heat exchanger
5. Water reservoir
6. Pump
7. Cooling unit
8. Waste/recycling reservoir
9. Output line
The drum(l), as one of the main components of the vacuum leather processing machine, allows recirculation of a liquid in the system using a drive system which can operate on single or double rollers or bronze beds. The main body of the
drum(l) can be produced in various sizes, in cylindrical, hexagonal, octagonal or any other geometric shape according to the intended operation type. The drum(l) can be installed on top of a concrete base or steel construction pods. The drum(l) can be used as a leather tanning machine, leather processing mixer, wet(humid) curing machine, dry curing machine or leather drum drying machine. The drum(l) can be made of five different materials, comprised of stainless steel, polypropylene, polyester, wood or polyethlylene. Body of the drum(l) circulates external oil or water or mechanically recirculates internal process water through a heater with its double walled structure.
In the vacuum leather processing machine and method subject to the invention the leather or textile product intended for convection or modification is placed into the drum(l). The product placed in the drum(l) is washed at a temperature level between 25° C to 50° C according to the amount of product or the intended formula. The washing time varies according to factors like the type, the size or the colour of the product placed in the drum(l). Some example operations are shown in Table-1 and Table-2 below. The data provided in Table-1 and Table-2 are example operations only intended for information purposes and do not cover the entirety of the invention.
The washing operation makes the product in the drum(l) soften and pulls the fibres of the product apart to a degree. The increase in temperature and moisture in the drum(l) achieve in result of washing negatively affects the application of vacuum in the drum(l). The moisture is remoevd from the drum(l) through a valve placed in the internal wall of the drum(l) for this purpose. Thus, an environment convenient for establishing a vacuum is achieved in the drum(l).
A blower(2) connected to the drum(l) is used to help establish vacuum in the drum(l). The blower(2) allow reduction of the internal pressure in the drum(l) to the level of 600 to 750 mmHg. Even when pressure level is reduced with the help of the blower(2) the required level of vacuum cannot be achieve with this alone. At least one booster(3) must be connected to the blower(2) in order to reach the desired level of vacuum. With addition of the booster(3) the internal pressure of the drum(l) is moved from 600 to 750 mmHg level to 750 to 900 mmHg. A vacuum pump can also be used as an alternative to the booster(3).
After application of negative pressure, water and chemical materials are sent into the drum(l). With the vacuum applied in the drum(l) all leather tanning procedures including the wetting, liming, pickling, depickling, chorming, retainage, dyeing and wet curing can be performed. As the fibre pores in the product in the drum(l) are sufficiently pulled open with the effect of the vacuum, water and chemicals can penetrate into these pores. The pressure level in the drum(l) should be kepts at a minimum average of 650 mmHg during the process in order to allow the water and chemicals to penetrate into the fibres. Some of the vacuum level is lost during input of water and chemicals into the drum(l). Drive system of the drum(l) can be provided with five different methods, comprising chain gear, steel gear, castermid gear, derlin gear and belt pulley power transfer.
Upon input of water and chemicals into the drum(l) the level of moisture and temperature in the drum(l) rises again. The moisture and temperature levels in the drum(l) can be monitored by the hygrometer and thermometer connected to the drum(l) and adjsuted accordingly from the control panel. The system can measure the temperature and moisture levels in the drum(l) while the drum(l) working during the process and control parameters like process water temperature, chemical material dosaging amounts, water intake amounts and operation time from the control panel. The control panel can be in digital or mechanical structure according to preference.
While the drum(l) is cooled at the outer walls due to the applied vacuum, the temperature inside the drum(l) constantly rises. The water and chemicals inside the drum(l) transition into gaseous phase due to the increasing temperature. The increased level of moisture in the drum(l) constitutes a hazard for the blower(2). The gas particles formed inside the drum are pulled into the blower(2) due to the pressure applied by the blower(2). When gas particles travel into the blower(2) it cannot work at 100% performance and its efficiency is reduced. To prevent this from happening, the control panel will stop vacuum operation when the spot moisture and temperature levels measured by the hygrometer and the thermometer exceeds the preset moisture and temperature levels. Then the water and chemicals which have transitioned into gaseous phase are removed from the drum(l) through the output I i ne(9) connected to the inner surface of the drum(l). The gas particles are conveyed to the heat exchanger(4) through the output line. When they pass through the heat exchanger(4) the gas particles condense and
transition to liquid phase. The liquid material generated in this process is transferred to waste/recycling reservoir(8). After this vacuum is again applied into the drum(l) by help of the blower(2) and the booster(3) to bring the internal pressure of the drum(l) to the desired level. When the pressure reaches the desired level the water and chemicals inside the waste/recycling reservoir(8) are redirected into the drum(l) to provide recycling in the system. When the process is concluded waste liquids in lesser amounts in comparison to current state of the art are collected in the waste/recycling reservoir(8). This drum(l) process is repated for each procedure to be applied on the product as well as according to the formula. For the heat exchanger(4) element used in the process plate exchangers or pipe exchanger can be used, and external heating can be provided thorugh heater fluids using resistance heaters. As an alternative, the process water can be connected to a pipe, exchnager or heater tank through a mechanical recirculation system for recirculating heating of the internal process water. As another alternative, a forced mechanical circulation system can be installed to pass the process water in the drum(l) through a dobule walled(hot oil or steam heated) pipe to provide mechanical recirculating heating without using any pump.
Wet curing and dry curing operations can be performed in the vacuum leather processing machine subject to the invention. Connection of a hot air circulation system into the drum(l) is sufficient for enabling such operations.
This application both decreases consumption rate of the water and chemicals sent into the drum(l) to dye the product in the drum(l) and helps the water and chemicals penetrate into all fibres of the product. The decreased amount of water and chemicals consumed in the drum(l) also decreased the amount of waste generated during operation.
It is observed that as pressure drops in vacuum leather processing operation the temperature levels of the machine elements including the drum(l), the blower(2) and the booster(3) also increase. This can lead to damage on the drum(l), the blower(2) and the booster(3) elements. In order to prevent this from happening cooling systems are installed on the outer surfaces of the drum(l), the blower(2) and the booster(3). This cooling system may have a double walled structure according to preference. The water circulating in the cooling system between the two walls of the drum(l), the blower(2) and the booster(3) starts to heat up during the process. The heated water in the cooling system is first passed through the
heat exchanger(4) to lose some of its heat and then transferred to the water reservoir(5). After this initial cooling step the water in the water reservoir(5) is moved to the cooling unit(7) by help of the pump(6). After being fully cooled down in the cooling unit(7) the water is returned to the cooling system on the outer surfaces of the drum(l), the blower(2) and the booster(3). These steps are repeated as long as the process continues (see. Image-1).
Claims
CLAIMS A machine with a vacuum line used to process the leather or textile products, characterised by elements including; a. At least one drum(l) wherein the leather or textile product to be processed will be placed, having a cooling system on the outer surface and an output line(9) through which the moisture can be removed; b. At least one blower(2) which is connected to the said drum(l) to apply pressure into the drum(l); c. At least one booster(3) which is connected to the said blower(2) and used to enhance the level of pressure applied into the said drum(l); d. At least one cooling unit(7) used to cool down the water circulated through the system in order to balance the temperature of the said drum(l), blower(2) and booster(3); and e. At least one heat exchanger(4) allowing collection and condensation of gas particles generated in the said drum(l). A vacuum method used to process the leather or textile products, characterised by process steps including; a. Placement of the leather or textile product to be processed into the drum(l) and reduction of the internal pressure of the drum(l) by help of the blower(29) while the lid of the drum(l) is closed; b. Further reduction of the internal pressure of the said drum(l) whose internal pressure was reduced by the said blower(2); c. Pumping of cold water into the system from the cooling unit(7) to lower the temperature levels of the said drum(l), blower
(2) and booster
(3) elements which rise as the pressure is reduced; d. Transfer of the gas particles generated in the said drum(l) as the temperature rises through an output line(9) located inside the drum(l) to the heat exchanger(4) in order to condense the gas particles and transition them into liquid phase and transfer of the liquid generated in result of this operation into the waste/recycling reservoir(8). A blower(2) according to Claim-1, characterised by having a cooling system on the outside surface.
4. A booster(3) according to Claim-1, characterised by having a cooling system on the outside surface.
5. A drum(l) according to Claim-1, characterised by having a double internal walled cooling system.
6. A blower(2) according to Claim-1, characterised by having a double internal walled cooling system.
7. A booster(3) according to Claim-1, characterised by having a double internal walled cooling system.
8. A machine according to Claim-1, characterised by having at least one water reservoir(5) wherein the cooling water recirculated in the system is stored.
9. A machine according to Claim-1, characterised by having at least one pump(6) providing drive for flow of the cooling water recirculated in the system.
10. A drum(l) according to Claim-1, characterised by having a cylindrical structure.
11. A drum(l) according to Claim-1, characterised by having a hexagonal structure.
12. A drum(l) according to Claim-1, characterised by having an octagonal structure.
13. A drum(l) according to Claim-1, characterised by having a geometric form suitable for the leath type to be processed.
14. A drum(l) according to Claim- 1, characterised by being made from steel material.
15. A drum(l) according to Claim-1, characterised by being made from polypropylene material.
16. A drum(l) according to Claim-1, characterised by being made from polyester material.
17. A drum(l) according to Claim-1, characterised by being made from wood material.
18. A drum(l) according to Claim-1, characterised by being made from polyethylene material.
19. A machine according to Claim-1, characterised by having at least one vacuum pump in its system.
20. A drum(l) according to Claim-1, characterised by having a chain gear used in operation of the drive system.
21. A drum(l) according to Claim-1, characterised by having a steel gear used in operation of the drive system.
22. A drum(l) according to Claim-1, characterised by having a castamid gear used in operation of the drive system.
23. A drum(l) according to Claim-1, characterised by having a derlin gear used in operation of the drive system.
24. A drum(l) according to Claim-1, characterised by having a belt pulley power transfer system used in operation of the drive system.
25. A drum(l) according to Claim-1, characterised by having at least one conrol panel located on the said drum(l) which mechanically or digitally allow monitoring and control of process water temperature, chemical material dosage amounts, water intake amounts and operation time during the process.
26. A machine according to Claim-1, characterised by having a concrete base and/or steel construction pads on which the said drum(l) is positioned.
27. A machine according to Claim-1, characterised by having at least one double walled pipe with hot oil and/or steam heating through which the process water from inside the drum(l) is passed to provide heating by mechanical recirculation without using any pump.
28. A machine according to Claim-1, characterised by having at least one hot air circulation system connected to the inside of the drum(l) to allow performance of wet curing, dry curing or drying operations.
29. A machine according to Claim-1, characterised by having an internal temperature between 25°C to 50°C inside the said drum(l) during the washing operation according to the amount and/or formula of the product placed inside the drum(l).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/TR2021/050108 WO2022169429A1 (en) | 2021-02-05 | 2021-02-05 | Innovation in vacuum leather processing machine and method |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/TR2021/050108 WO2022169429A1 (en) | 2021-02-05 | 2021-02-05 | Innovation in vacuum leather processing machine and method |
Publications (1)
Publication Number | Publication Date |
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WO2022169429A1 true WO2022169429A1 (en) | 2022-08-11 |
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PCT/TR2021/050108 WO2022169429A1 (en) | 2021-02-05 | 2021-02-05 | Innovation in vacuum leather processing machine and method |
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Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2005083168A1 (en) * | 2004-02-20 | 2005-09-09 | The Procter & Gamble Company | Wash-drier and method using the same |
US20180038037A1 (en) * | 2016-08-08 | 2018-02-08 | Lap Shun Hui | Systems and methods for washing and drying using an altered pressure environment |
-
2021
- 2021-02-05 WO PCT/TR2021/050108 patent/WO2022169429A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2005083168A1 (en) * | 2004-02-20 | 2005-09-09 | The Procter & Gamble Company | Wash-drier and method using the same |
US20180038037A1 (en) * | 2016-08-08 | 2018-02-08 | Lap Shun Hui | Systems and methods for washing and drying using an altered pressure environment |
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