System and method for proactive dyeing for cellulosic and cellulosic blended textiles

Abstract

A system and method for cationization of textiles preferably starting with the dry raw greige tubular or open width goods that are made from either a cellulosic or cellulosic blended fabric. The system can include an inducer apparatus with chemical dosification system. In a preferred embodiment, the dry tubular goods are sent in a flat configuration to a first impregnation tank where it receives a multi-functional reaction fluid. After leaving the first impregnation tank, the now wet fabric is turned (when in a tubular width fabric form) by a turning unit and then sent to a second impregnation tank where it again is exposed to the multi-functional reaction fluid. The turning of the fabric causes the side edge positions of the flat tubular fabric to change its physics dynamics which allows for the multi-functional reaction fluid to be evenly applied to the entire fabric. Turning is not needed for open with fabric as it is flat, thus having only one dynamic when analyzed with physics.

What is claimed is: 
     
         1 . A system for cationization of textiles starting with the dry tubular width fabric that are made from either a cellulosic or cellulosic blended fabric in a raw greige stage directly from knitting for cost efficiency, or in a pre-scoured greige or pre-bleached greige condition, the system comprising:
 a fabric feeding unit for spreading and forwarding tubular width fabric for inducing prior to dyeing, wherein in a spread configuration the tubular fabric is forwarded in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric;   a first chemical impregnation tank in communication with the fabric feeding unit and receiving the tubular width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a multi-functional reaction fluid able to treat fabric in a raw greige dirty condition or in a scoured or bleached condition;   a turning unit receiving the tubular width fabric exposed to the multi-function reaction fluid after the tubular fabric exits the first chemical impregnation tank, the turning unit turning the tubular fabric at an angle to cause the location of the initial set of edges to now be substantially flat fabric and no longer at an edge position, wherein continued travel and turning of the tubular fabric causing different areas of the tubular width fabric to become a new set of edges on each side of the traveling flat tubular fabric; and   a second chemical impregnation tank in communication with the turning unit, the second chemical impregnation tank receiving the turned wet tubular width fabric from the turning unit and after the turning unit has turned the wet tubular width fabric, the second chemical impregnation tank defining a second interior area containing a second amount of the multi-functional reaction fluid able to treat fabric;   
     
     
         2 . The system for cationization of  claim 1  wherein the fabric is preferably raw dry greige goods. 
     
     
         3 . The system for cationization of  claim 1  further comprising a fabric bridge leading to the turning unit, the fabric bridge having width measurement sensors and spreaders, the width measurement sensors reading any changes in width of the fabric after the fabric leaves the first impregnation bath to compensate for the dry moving fabric getting wet and thus thinner, wherein again the width measurements are used by the spreaders when guiding the fabric to prevent ripping or twisting of the fabric. 
     
     
         4 . The system for cationization of  claim 1  wherein a range for the angle is about 45-90° degrees. 
     
     
         5 . The system for cationization of  claim 1  wherein the first chemical impregnation tank is in fluid communication with the second chemical impregnation tank through a first conduit providing communication between the first interior area and the second interior area and serving as an inlet for providing the second amount of the multi-functional reaction fluid into the second interior area. 
     
     
         6 . The system for cationization of  claim 5  wherein the first chemical impregnation tank is also in fluid communication with the second chemical impregnation tank through a second conduit providing communication between the first interior area and the second interior area and serving as an outlet for returning at least some of the second amount of the multi-functional reaction fluid from the second interior area back to the first interior area in order to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area. 
     
     
         7 . The system for cationization of  claim 1  further comprising a first blowing air unit for ballooning the fabric impregnated with the multi-functional reaction fluid to increase penetration, evenness of penetration and making the fabric perfectly flat going directly into the first squeeze to prevent overlaps or twists of the wet greige fabric with the multi-functional reaction fluid after it exits the first impregnation tank and prior to being turned by the turning unit. 
     
     
         8 . The system for cationization of  claim 1  wherein the first chemical impregnation tank having a first displacing block(s) disposed within the first interior area to reduce an available volume amount within the first interior area. 
     
     
         9 . The system for cationization of  claim 8  wherein the second chemical impregnation tank having a second displacement block(s) disposed within the second interior area to reduce an available volume amount within the second interior area. 
     
     
         10 . The system for cationization of  claim 1  wherein the second chemical impregnation tank disposed at an angle with respect to a position of the first chemical impregnation tank depending on the desired degree of the turning unit and if the turning unit is place between the tanks. 
     
     
         11 . The system for cationization of  claim 1  further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer rope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention. 
     
     
         12 . The system for cationization of  claim 11  wherein the A-frame is positioned on a movable floor guided by a center winder sensor of the fabric winding assembly so that winding by the winding assembly is centered to avoid air pockets and allow for fabric edge on edge winding. 
     
     
         13 . The system for cationization of  claim 1  wherein the first impregnation tank, the turning unit and the second impregnation tank are enclosed within a housing, the housing having an exhaust fan and outlet for worker safety with a control panel place outside of an enclosed area defined by the housing. 
     
     
         14 . The system for cationization of  claim 7  further comprising a second blowing unit for ballooning the fabric impregnated with the multi-functional reaction fluid after it exits the second impregnation tank for even penetration and preventing wrinkles going into a second squeeze as width is automatically regulated by spreaders which are given current with by sensors. 
     
     
         15 . The system for cationization of  claim 1  wherein the multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric. 
     
     
         16 . A system for cationization of textiles starting with the tubular width fabric that are made from either a cellulosic or cellulosic blended fabric, the system comprising:
 a fabric feeding unit for forwarding a fabric in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric;   a first chemical impregnation tank in communication with the fabric feeding unit and receiving the tubular width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a multi-functional reaction fluid;   a mixer having an outlet in fluid communication with the first chemical impregnation tank for introducing the cold multi-functional reaction fluid into the first interior area of the first chemical impregnation tank;   a first blowing air unit for ballooning the fabric impregnated with the multi-functional reaction fluid to increase penetration, prevent wrinkles and evenness of the multi-functional reaction fluid after it exits the first impregnation tank;   a first squeezing rollers unit with pressure control pistons positioned above the first air blowing unit and the first chemical impregnation tank, wherein the fabric impregnated with the multi-functional reaction fluid from the first impregnation tank is fed through and squeezed by the first squeezing rollers unit and prior to being received by a turning unit;   a turning unit receiving the tubular fabric exposed to the multi-function reaction fluid after the tubular fabric exits the first chemical impregnation tank, the turning unit turning the tubular fabric at an angle to cause the location of the initial set of edges to now be approximately centrally located with respect to the substantially flat fabric and no longer at an edge position, wherein continued travel and turning of the tubular fabric causing different areas of the tubular fabric to become a new set of edges on each side of the traveling flat tubular fabric;   a fabric bridge leading to the turning unit, the fabric bridge having width measurement sensors and spreaders, the width measurement sensors reading any changes in width of the fabric after the fabric leaves the first impregnation bath, wherein the width measurements are used by the spreaders when guiding the fabric to prevent ripping, wrinkling or twisting of the fabric;   a second chemical impregnation tank in communication with the turning unit, the second chemical impregnation tank receiving the turned wet tubular fabric from the turning unit and after the turning unit has turned the wet tubular fabric, the second chemical impregnation tank defining a second interior area containing a second amount of the cold multi-functional reaction fluid, in fluid communication to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area;   a second squeezing rollers unit positioned above the air blowing unit and the second chemical impregnation tank, wherein the fabric impregnated with the multi-functional reaction fluid from the second chemical impregnation tank is fed through and squeezed by the second squeezing rollers unit;   wherein the second chemical impregnation tank disposed at an angle with respect to a position of the first chemical impregnation tank;   wherein the multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric.   
     
     
         17 . The system for cationization of  claim 16  wherein the fabric to be induced is raw dry greige goods directly from the knitting or weaving department. 
     
     
         18 . The system for cationization of  claim 16  wherein the angle is between about 45-90° degree. 
     
     
         19 . The system for cationization of  claim 16  further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer tope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention. 
     
     
         20 . A method for evenly applying a multi-functional reaction fluid to a tubular width knit fabric being fed through a cationization system in a substantially flat configuration to define an initial set of edges located on each side of the flatted fabric, the fabric being a cellulosic or cellulosic blended fabric, comprising the steps of:
 a. exposing a length of tubular width knit fabric to a first amount of a multi-functional chemistry solution disposed within a first inducing bath,   b. turning the tubular width knit fabric after the tubular knit fabric has exited out of the first inducing bath to cause the location of the initial set of edges to now be approximately centrally located with respect to the substantially flat fabric and no longer at an edge position and also causing different areas of the tubular fabric to become a new set of edges thus creating new physics dynamics for the fabric for even distribution of chemistry on each side of the traveling flat tubular fabric; and   c. exposing the tubular width knit fabric after turning, to a second amount of the multi-functional chemistry solution disposed within a second inducing bath.   
     
     
         21 . The method for evenly applying a multi-functional reaction fluid to a tubular width knit fabric of  claim 20  further comprising the step of automatically winding the fabric without human intervention by a self-catching winding assembly, the self-catching winding assembly having a winder with outwardly extending needles and an A-frame with the winding assembly rotatably connected to the winder. 
     
     
         22 . The method for evenly applying a multi-function reaction fluid to a tubular width knit fabric of  claim 21  further comprising the step of allowing the fabric to remain winded for a period of time to cause the multi-functional reaction fluid to bond to the fabric as the fluid slowly warms up and over time with further warming up of the fluid creating one or more positive charge sites on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric 
     
     
         23 . A system for cationization of textiles starting with the open-width goods that are made from either a cellulosic or cellulosic blended fabric, the system comprising:
 a fabric feeding unit containing a spreader spread so the open-width fabric is forwarded in a flat configuration;   a first chemical impregnation tank in communication with the fabric feeding unit and receiving the open-width fabric from the fabric feeding unit, the first chemical impregnation tank defining a first interior area containing a first amount of a cold multi-functional reaction fluid;   a mixer having an outlet in fluid communication with the first chemical impregnation tank for introducing the cold multi-functional reaction fluid into the first interior area of the first chemical impregnation tank;   a first squeezing rollers unit with pressure control pistons positioned above the first chemical impregnation tank, wherein the fabric impregnated with the cold multi-functional reaction fluid from the first impregnation tank is fed through and squeezed by the first squeezing rollers unit;   a second chemical impregnation tank in communication with the fabric bridge, the second chemical impregnation tank receiving the wet open-width fabric after the fabric has left the first chemical impregnation, the first chemical impregnation tank is also in fluid communication with the second chemical impregnation tank through a second conduit providing communication between the first interior area and the second interior area and serving as an outlet for returning at least some of the second amount of the multi-functional reaction fluid from the second interior area back to the first interior area in order to maintain a homogenous multi-functional reaction fluid in both the first interior area and the second interior area;   a second squeezing rollers unit positioned above the second chemical impregnation tank, wherein the fabric impregnated with the cold multi-functional reaction fluid from the second chemical impregnation tank is fed through and squeezed by the second squeezing rollers unit;   wherein the cold multi-functional reaction fluid bonds to the cellulose or cellulosic blended fabric as the fluid slowly warms up and over time with further warming up of the fluid one or more positive charge sites are created on the fabric for bonding with negative charge sites of a fabric dye during a dyeing process for the fabric.   
     
     
         24 . The system for cationization of  claim 23  wherein the goods are raw dry greige goods. 
     
     
         25 . The system for cationization of  claim 23  further comprising a fabric winding assembly for receipt and winding of fabric after the fabric has exited the second impregnation chemical tank, the assembly having an A-frame and a winder rotatably connected to the A-frame, the winder having an outer surface having a plurality of upwardly extending needles, wherein each of the needles having a hook portion at an outer tope end for grabbing the fabric such that the winding assembly is self-catching and winding assembly can be started/threaded with respect to an initial fabric on a center beam of the A-frame without human intervention. 
     
     
         26 . The system for cationization of  claim 25  wherein the A-frame is positioned on a movable floor guided by a sensor of the fabric width on the A-frame so the pressure on the fabric winding is even and not too tight. 
     
     
         27 . The system for cationization of  claim 23  further comprising a covering to create a “closed” system and minimize or prevent exposure to an vapors created by chemical reaction of the reaction fluid; wherein further comprising a control panel for controlling operation of the system with the control disposed on an elbow arm device or mounted outside an area enclosed by the covering; wherein the tanks are enclosed by the covering and the covering is provided with an exhaust system. 
     
     
         28 . The system for cationization of  claim 27  wherein dyeing of the cationized cellulosic fabric is performed in the exhaust system and in a dyeing cycle treatment steps include washing, bleaching, dyeing, neutralization with a finishing pH of 5.7-5.9, with current chemistry and an addition of boric acid as a scent preventing agent for preventing degradation of TMA and a fishy smell often appearing during standard textile drying. 
     
     
         29 . The method for evenly applying a multi-function reaction fluid to a tubular width knit fabric of  claim 20  wherein an ionic cross-linked cationic fibrous material in the raw greige fabric stage directly from knitting or weaving in a practical and in a production manner though a cold pad-batch method is produced involving the following steps inducing mono functional or multifunctional cationic polymer with the epoxy chain attaching to the cellulosic fibers in a high alkali solution comprising a mono cationic polymer 2,3-epoxypropyl trimethyl ammonium chloride (EPTAC) with the EPTAC formed from 3-chloro-2-hydroxypropyl trimethyl ammonium chloride (CHTAC) with an alkali, sodium hydroxide (NaOH) and providing boric acid in a dyeing process to prevent TMA degradation and prevent a permanent fishy smell.