Apparatus and method for pre-shrinking a wet fabric prior to drying

Abstract

An apparatus and method for pre-shrinking a wet fabric prior to drying. The apparatus includes, among other components, a balloon extractor station and a hydro-sizer compression station. The balloon extractor station removes some water from the wet fabric. The hydro-sizer compression station is operatively connected to, and disposed downstream of, the balloon extractor station, and compresses the wet fabric in a lengthwise direction, and in so doing, pre-shrinks the wet fabric prior to drying. The method includes, among other steps, extracting some water from the wet fabric so as to form a hydro-extracted and wet fabric, compressing lengthwise the hydro-extracted and wet fabric so as to form a compacted and wet fabric that is now pre-shrunk prior to drying, and drying the compacted and wet fabric so as to form a compacted and dry fabric.

The invention claimed is: 
     
         1 . An apparatus for pre-shrinking a wet fabric prior to drying, comprising:
 a) a balloon extractor station; and   b) a hydro-sizer compression station;   wherein said balloon extractor station is for removing some water from the wet fabric;   wherein said hydro-sizer compression station is operatively connected to said balloon extractor station;   wherein said hydro-sizer compression station is disposed downstream of said balloon extractor station; and   wherein said hydro-sizer compression station is for compressing the wet fabric in a lengthwise direction, and in so doing, pre-shrinks the wet fabric prior to drying.   
     
     
         2 . The apparatus of  claim 1 , further comprising a knit washer station;
 wherein said knit washer station is operatively connected to said balloon extractor station; and   wherein said knit washer station is disposed downstream of said balloon extractor station.   
     
     
         3 . The apparatus of  claim 2 , further comprising a twin balloon pad station;
 wherein said twin balloon pad station is for padding on chemical softeners or chemical lubricants;   wherein said chemical softeners of said twin balloon pad station or said chemical lubricants of said twin balloon pad station include non-ionic, cationic, polyethylene, silicone, or soil and stain release agents;   wherein said twin balloon pad station is for removing excess water and excess of said chemical softeners of said twin balloon pad station or said chemical lubricants of said twin balloon pad station from the wet fabric;   wherein said twin balloon pad station is operatively connected to said knit washer station;   wherein said twin balloon pad station is disposed downstream of said knit washer station;   wherein said hydro-sizer compression station is operatively connected to said twin balloon pad station; and   wherein said hydro-sizer compression station is disposed downstream of said twin balloon pad station.   
     
     
         4 . The apparatus of  claim 1 , further comprising an entry system station;
 wherein said balloon extractor station is operatively connected to said entry system station;   wherein said balloon extractor station is disposed downstream of said entry system station;   wherein said entry system station includes:   a) an hydraulic turntable;   b) a twist sensor;   c) a driven cloth lifter;   d) a motorized pot-eye de-twister; and   e) “O” ring guiders;   wherein said “O” ring guiders of said entry system station have powered width control;   wherein said “O” ring guiders of said entry system station have hole detectors;   wherein said twist sensor of said entry system station is for automatic de-twisting; and   wherein said driven cloth lifter of said entry system station is for automatic de-twisting.   
     
     
         5 . The apparatus of  claim 1 , wherein said balloon extractor station includes a driven feed roll;
 wherein said driven feed roll of said balloon extractor station is for drawing the wet fabric through ring guides and into a pre-wet extracting scary;   wherein said balloon extractor station includes an extracting scray;   wherein said extracting scray of said balloon extractor station is for automatic speed control and air for ballooning the wet fabric; and   wherein said extracting scray of said balloon extractor station has an idler/dancer assembly.   
     
     
         6 . The apparatus of  claim 1 , wherein said balloon extractor station includes a pair of extracting squeeze rolls; and
 wherein each extracting squeeze roll of said balloon extractor station is made from a metal or a metal core covered in polyurethane, rubber, or other synthetic compounds.   
     
     
         7 . The apparatus of  claim 2 , wherein said knit washer station includes a continuous washing chamber;
 wherein said continuous washing chamber of said knit washer station is made from stainless steel; and   wherein said continuous washing chamber of said knit washer station has eight individual compartments.   
     
     
         8 . The apparatus of  claim 7 , wherein said eight individual compartments of said continuous washing chamber of said knit washer station include:
 a) eight immersion rolls;   b) eight carrier rolls;   c) four nip roll assemblies;   d) two directional rolls;   e) displacement baffles;   f) air injection assemblies;   g) compartment drains; and   h) overflow drains; and   wherein said four nip roll assemblies of said eight individual compartments of said continuous washing chamber of said knit washer station have pneumatic loading.   
     
     
         9 . The apparatus of  claim 2 , wherein said knit washer station includes a PH system;
 wherein said PH system of said knit washer station has:   a) an acid circulation pump;   b) an electronic metering pump;   c) integral piping; and   d) a PH probe; and   wherein said PH probe of said PH system of said knit washer station has a transmitter.   
     
     
         10 . The apparatus of  claim 2 , wherein said knit washer station includes a soap dispensing system; and
 wherein said soap dispensing system of said knit washer station has:   a) an electronic metering pump; and   b) integral piping.   
     
     
         11 . The apparatus of  claim 7 , wherein said knit washer station includes a water heating system;
 wherein said water heating system of said knit washer station has:   a) a heat exchanger; and   b) a steam control valve;   wherein said steam control valve of said water heating system of said knit washer station has an RTD; and   wherein said RTD of said steam control valve of said water heating system of said knit washer station is for water temperature measurement in said continuous washing chamber of said knit washer station.   
     
     
         12 . The apparatus of  claim 11 , wherein said water heating system of said knit washer station has:
 a) a temperature controller;   b) piping; and   c) fittings;   wherein said piping and said fittings of said water heating system of said knit washer station connect said steam control valve of said water heating system of said knit washer station to said continuous washing chamber of said knit washer station; and   wherein said temperature controller of said water heating system of said knit washer station has a control valve transducer.   
     
     
         13 . The apparatus of  claim 3 , wherein said twin balloon pad station includes an extracting scray;
 wherein said extracting scray of said twin balloon pad station is for automatic speed control and air for ballooning the wet fabric; and   wherein said extracting scray of said twin balloon pad station has an idler/dancer assembly.   
     
     
         14 . The apparatus of  claim 3 , wherein said twin balloon pad station includes:
 a) a pair of extracting squeeze rolls;   b) a chemical application pan; and   c) a processing scray;   wherein said processing scray of said twin balloon pad station is for automatic speed control;   wherein said processing scray of said twin balloon pad station has an idler/dance assembly;   wherein said chemical application pan of said twin balloon pad station has air for ballooning the wet fabric; and   wherein said chemical application pan of said twin balloon pad station is made from stainless steel.   
     
     
         15 . The apparatus of  claim 14 , wherein said twin balloon pad station includes:
 a) a pair of padding rolls;   b) a solution controller; and   c) after-spreaders;   wherein said solution controller of said twin balloon pad station is for automatic control of volume of the chemical softeners or the chemical lubricants;   wherein said after-spreaders of said twin balloon pad station have a pair of spreaders; and   wherein said pair of spreaders of said after-spreaders of said twin balloon pad station have:   a) powered width change; and   b) hole detectors.   
     
     
         16 . The apparatus of  claim 15 , wherein each extracting squeeze roll of said twin balloon pad station and each padding roll of said twin balloon pad station is made from a metal or a metal core covered in polyurethane, rubber, or other synthetic compounds. 
     
     
         17 . The apparatus of  claim 1 , wherein said hydro-sizer compression station includes:
 a) an edge-drive spreading unit;   b) a pair of spreaders;   c) a feed roll;   d) a retard roll; and   e) a shoe assembly;   wherein said shoe assembly of said hydro-sizer compression station is for wet compacting;   wherein said hydro-sizer compression station is for compressing the wet fabric in the lengthwise direction, and in so doing, pre-shrinks the wet fabric prior to drying, through independent speed control of said feed roll of said hydro-sizer compression station and said retard roll of said hydro-sizer compression station;   wherein said pair of spreaders of said hydro-sizer compression station have:   a) powered width change; and   b) hole detectors; and   wherein said shoe assembly of said hydro-sizer compression station has a lower impact blade/shoe.   
     
     
         18 . The apparatus of  claim 17 , wherein each of said feed roll of said hydro-sizer compression station and said retard roll of said hydro-sizer compression station is made from a metal or a metal core covered in polyurethane, rubber, or other synthetic compounds; and
 wherein said lower impact blade/shoe of said shoe assembly of said hydro-sizer compression station is made from metal or synthetic polymers.   
     
     
         19 . The apparatus of  claim 1 , further comprising a folding station;
 wherein said folding station includes:   a) a self-adjusting and descending-rate drop table; and   b) a fabric transport conveyor;   wherein said fabric transport conveyor of said folding station has a top;   wherein said fabric transport conveyor of said folding station is for delivering the wet fabric to said self-adjusting and descending-rate drop table of said folding station; and   wherein said self-adjusting and descending rate-drop table of said folding station is for controlling distance of travel of the wet fabric from said top of said fabric transport conveyor of said folding station to said self-adjusting and descending-rate drop table of said folding station for preventing compaction percentage of length tension of the wet fabric hanging from said fabric transport conveyor of said folding station from being reduced or pulled out.   
     
     
         20 . A method for pre-shrinking a wet fabric prior to drying, comprising the steps of:
 a) entering the wet fabric into a balloon extractor station via an entry system station so as to form an entered and wet fabric;   b) extracting some water from the wet fabric via a balloon extractor station so as to form a hydro-extracted and wet fabric;   c) washing the hydro-extracted and wet fabric via a knit washer station so as to form a washed, hydro-extracted, and wet fabric;   d) applying chemical softeners or chemical lubricants to the washed, hydro-extracted, and wet fabric via a twin balloon pad station so as to form a chemically applied, washed, hydro-extracted, and wet fabric;   e) removing excess of the chemical softeners or the chemical lubricants from the chemically applied, washed, hydro-extracted, and wet fabric via the twin balloon pad station so as to form an excess chemically removed, washed, hydro-extracted, and wet fabric;   f) compressing lengthwise the excess chemically removed, washed, hydro-extracted, and wet fabric via a hydro-sizer compression station so as to form a compacted, hydro-extracted, and wet fabric that is now pre-shrunk prior to drying;   g) drying the compacted, hydro-extracted, and wet fabric so as to form a compacted and dry fabric; and   h) folding the compacted and dry fabric via a folding station so as to form a folded, compacted, and dry fabric.