Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Case 16~7
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CLEANING AID FOR DYEING APPARATUS
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~ This invention relates to an apparatus for the application of dyestuffs
- to textile materials, and, more particularly, to a device useful in
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cleaning the dye-emitting orifices and other dye handling parts associated
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Many techniques are known for the application of dyestuffs to textile
substrates, and particularly the application of dyestuffs to such
substrates in a pattern configuration. Among such techniques, it has been
~ 10 found advantageous to apply dye in the form of discrete streams of dye,
b""' formed and directed by a plurality of dye-emitting orifices. Ideally, each
individual stream may be lntermittently interrupted or diverted in
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` , accordance with pattern information. Dyeing systems of this latter type
;'~ are generally described in greater detail in, for example, U.S. Patent
Numbers 3,894,413, 3,942,343, 4,033,154, 4,034,584, 4,116,626,
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' 4,309,881, 4,434,632, and 4,584,854.
These systems are commonly configured in the form of a conveyor which
, transports the substrate to be dyed under a plurality of such continuously
flowing discrete dye streams. In a preferred embodiment, a plurality of
dye orifices, each directed at the substrate, are arranged in several
individual linear arrays positioned generally above and across ,the
substrate path in spaced, parallel alignment, with each array being
associated with a separate source (e.g., a different color) of liquid dye.
Generally, each of the arrays is positioned ln close proximity to the
substrate to be dyed, with typical clearance between the array and the
substrate surface being substantially less than one inch. The individual
continuously flowing dye streams in a given array are normally directed
onto the substrate surface. However, by means of a transverse intersecting
stream of diverting air which is aligned with each dye stream and which is
actuated or interrupted in response to externally supplied pattern
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~- information, the continuously flowing stream may be directed into a
collection chamber or catch basin so as to prevent any dye from contacting
the substrate
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~ To accurately control the amount of dye applied to a given location on
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the material during the dyeing operation, and to insure that the dye
strikes the material in a very small, precise spot, the lower portion of
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the collection chamber contains a collector plate supportably positioned in
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. spaced relation above the lower wall of the collection chamber. This
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collector plate is adjustably attached to the lower wall of the collection
chamber by way of an elongate collector plate support member which forms an
extension of the lower wall of the collection chamber. By means of careful
. adjustment of the position of the collector plate relative to the collector
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plate support member, the leading edge of the collector plate can be
accurately positioned relative to the dye discharge axes of the array to
insure prompt and precise interception of the streams when deflected.
Details of such a dyeing apparatus and collection chamber construction are
described and claimed in commonly assigned U.S. Patent Number 3,942,343,
referenced above. As described therein, each dye stream, when deflected,
passes across the edge of the collector plate and into the collection
chamber. Upon removal of the deflecting air stream, the stream,moves back
across the plate edge and resumes its normal path of travel toward the
material to be dyed.
Because each array may be supplied with a different dye stuff, dye of
different colors from several of the individual arrays may be directed onto
the same area of the substrate and blended on the substrate to produce a
wide variety of colors and patterns. One inherent difficulty in such
systems involves changing the dye in one or more of the individual arrays
to permit patterning using a different color or set of colors. All of the
previous dye in the array must be thoroughly purged from the apparatus
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prior to the introduction of the newly selected dye to prevent undesirable
shade changing of the newly selected dye.
This process usually involves the emptying of the dye reservoir and
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manifold associated with the chosen array, followed by a flushing operation
in which water is used as the working liquid rather than dye.
Additionally, sprays of water may be directed within the array to cleanse
all surfaces exposed to the previously used dye. After the flush water
reaches an acceptable level of residual dye content, the flushing operation
may be stopped and the newly selected dye introduced. This process has
heretofore required the entire dyeing operation to be halted and the
substrate removed from the apparatus to avoid staining of the substrate by
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the flush water, even if only one of the arrays required a color change.
Another inherent difficulty in such systems involves the partial or
complete blockage of one or more of the dye-emitting orifices in a given
array. When such blockages occur, the dye stream cannot deposit the
required quantity or configuration of dye on the substrate in response to
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the pattern information, and an undesired pattern anomaly results.
Previous efforts to clean such orifices have met with limited success.
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For example, U.S. Patent Numbers 3,892,109 and 4,148,668 disclose a
cleaning approach in which an array of jet washers may be mountçd in a
carriage arrangement which permits the individual washers to be manually
positioned opposite, and in axial alignment with, the dye-emitting
orifices. Pressurized water or other fluid may then be directed from the
washer orifices into the dye orifices, dislodging and removing any
obstructions within the orifices. This method can be used to clean
multiple arrays of orifices in a single pass of the wash carriage, but
requires the substrate to be moved away from the arrays to provide proper
clearance for the carriage between the arrays and the substrate surface.
This interrupts any dyeing or patterning operation, and, because of the
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resulting flow of dye-carrying rinse water falling from the array onto the
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~ substrate, usually results in the permanent soiling of that section of
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substrate under the arrays at the time of cleaning.
A less comprehensive, but simpler technique is to clear the individual
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- 5 dye orifices by inserting a wire or the like into the orifice bore.
However, this technique also requires the substrate to be moved away from
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the arrays in order to gain access to the dye orifice, and thereby halts
~',`.r any dyeing or patterning operation.
As noted above, either of the above methods requires an increase in the
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array-to-substrate spacing in order to accommodate the cleaning means.
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This requires the entire dyeing opera~ion to be halted for cleaning, even
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though a blockage may have occurred in only one array of a multiple array
apparatus.
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The invention disclosed herein comprises an improvement over such
existing techniques in that an individual array may be cleaned or supplied
with a change of dye while all other arrays associated with the apparatus
;` remain in operation. No increase in the array-to-substrate spacing is
` required. The invention disclosed herein a1so provides for both external
and internal cleaning of the array. Additionally, the invention disclosed
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herein prevents any soiling of the substrate as a result of such cleaning
or dye changing operation.
; These advantages are achieved through the use of a novel cleaning
device whereby a shutter or shield, positioned on a containment enclosure
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; comprising a part of the array, is removably interposed between the
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, 25 dye-emitting orifices and the substrate while water is sprayed and
: circulated within the array for the purpose of cleaning and unblocking the
orifices as well as cleaning and preparing all dye-contacting surfaces
within the array for receiving dye of a different color. The shield and
containment enclosure of this invention are designed to keep any washing
liquid from contacting the substrate
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Additional advantages and details of the novel containment apparatus
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having a moveable shutter which comprises the instant invention will be
~, better appreciated and understood following a reading of the detailed
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~ description below, when read in coniunction with the accompanying Flgures,
; 5 in which:
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Figure 1 is a diagrammatic side view of the array configuration of a
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'- dyeing apparatus of a kind for which the instant invention may be adapted,
depicting eight dye-emitting arrays positioned above a section of a
,~ substrate web to be patterned;
~ 10 Figure 2 is a schematicized diagram of a portion of the apparatus of
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Figure 1;
Figure 3 is a diagrammatic side view of two of the arrays depicted in
Figure 1, in which the right array is shown with the shutter device of the
instant invention in a closed or engaged position, while the left array is
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depicted with the shutter device in an open or disengaged position, and
; further is depicted with a set of proximity sensors in place to detect the
~ position of the shutter device;
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Figure 4 is a view similar to Figure 3, but taken along a vertical
plane which intersects the array at an interior location, as depicted in
Figure 8 along line IV-IV, to show the interior of the arrays. The right
array is depicted with a wash system engaged;
Figure 5 is an enlarged view of the right array of Figure 4, detailing
the presumed flow of water within the array during the cleaning operation
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' and showing such flow around the engaged or interposed shutter portion of
the present invention.
Figure 6 is a further enlargement of a portion of the view of Figure 5;
Figure 7 shows the array of Figure 5 with the secondary drain tray in a
lowered position, as for occasional maintenance;
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Figure 8 shows, in partial section, a rear view (i.e., view looklng
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from right to left in Figure 5) of the shutter/containment apparatus of the
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instant invention;
Figure 9 is a perspective diagrammatic view of the shutter/containment
apparatus of the instant invention, further showing a preferred means by
which the shutter may be actuated;
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, Figure 10 is a view of the shutter/containment apparatus of Figure 9,
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as seen along lines X-X of Figure 9 with the left most shutter shuttle
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assembly shown in partial section;
Figure 11 is a view of the shutter/containment apparatus of Figure 9,
as seen along lines XI-XI of Figure 9, with the gear boxes shown in partial
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~ Figure 1 depicts, in a side elevation view, a set of eight individual
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arrays 26 positioned within frame 22. These arrays form part of a pattern
i 15 dyeing machine to which the present invention is particularly suited. Each
array 26 is comprised of a plurality of dye jets, arranged in spaced
alignment, which extend generally above and across the width of substrate
; 12. Substrate 12 is supplied from roll 10 and is transported in turn under
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each array 26 by conveyor 14 driven by a suitable motor indicated generally
at 16. After being transported under arrays 26, substrate 12 ~ay be passed
through other dyeing-related process steps such as drying, fixing, etc.
Figure 2 depicts, in schematic form, a side elevation of one
dye-emitting array of the machine of Figure 1. For each such array shown
generally at 26, a separate dye reservoir tank 30 supplies liquid dye under
pressure, by means of pump 32 and dye supply conduit means 34, to a primary
dye manifold assembly 36 of the array. Primary manifold assembly 36
communicates with and supplies dye to dye sub-manifold assembly 40 (shown
in greater detail in Figures 5 and 6) at suitable locations along their
respective lengths. Both manifold assembly 36 and sub-manifold assembly 40
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1 31 ~1 41
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extend across the width of conveyor 14 on which the substrate to be dyed is
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transported. Sub-manifold assembly 40 is provided with a plurality of
spaced, generally downwardly directed dye passage outlets 52 (shown, e.g.,
in Figure 6) positioned across the width of conveyor 14 which produce a
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plurality of parallel dye streams which are directed onto the substrate
surface to be patterned.
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As shown in Figures 2 and 6, positioned in alignment with and
approximately perpendicular to each dve passage outlet 52 in sub-manifold
assembly 40 is the outlet of an air deflection tube 62. Each tube 62
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communicates by way of an air deflection conduit 64 with an individual air
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valve, illustrated collectively at "V" in Figure 2, which valve selectively
interrupts the flow of air to air tube 62 in accordance with pattern
information supplied by pattern control device 20. Each valve is, in turn,
connected by an air supply conduit to a pressurized air supply manifold 74
which is provided with pressurized air by air compressor 76. Each of the
valves V, which may be of the electromagnetic solenoid type, are
individually controlled by electrical signals from a pattern control device
t~ 20. The outlets of deflection tubes 62 direct streams of air which are
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` aligned with and impinge against the continuously flowing streams of dye
flowing from dye passage outlets 52 and deflect such dye strea~s into a
primary collection chamber or trough 80, from which liquid dye may be
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removed, by means of a suitable dye collection conduit means 82, to dye
reservoir tank 30 for recirculation.
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The pattern control device 20 for operating solenoid valves V may be
comprised of various pattern control means, such as a computer with pattern
- information storage capabilities. Desired pattern information from control
device 20 is transmitted to the solenoid valves of each array at
appropriate times in response to movement by conveyor 14 which is detected
: by suitable rotary motion sensor or transducer means 18 operatively
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associated with the conveyor 14 and connected to control device 20.
Details of one means to perform this function may be found in commonly
assigned U.S. Patent Number 4,033,154, issued July 5, 1977.
In a typical dyeing operation utiliz~ng such apparatus, so long as no
pattern information is supplied by control device 20 to the air valves V
associated with the array of dye outlets 52, the valves remain "open" to
permit passage of pressurized air from air manifold 74 through air supply
conduits 64 to continuously deflect all of the continuously flowing dye
streams from the dye outlets 52 into the primary collection chamber 80 for
recirculation. When the substrate 12 initially passes beneath the dye
outlets 52 of the individual arrays 26, pattern control device 20 is
actuated in suitable manner, such as manually by an operator. Thereafter,
signals from transducer 18 prompt pattern information from pattern control
device 20. As dictated by the pattern information, pattern control device
20 generates control signals to selectively "close" appropriate air valves
so that, in accordance with the desired pattern, deflecting air streams at
specified individual dye outlets 52 along the arrays 26 are interrupted and
the corresponding dye streams are not deflected, but instead are allowed to
continue along their normal discharge paths to strike the substrate 12.
Thus, by operating the solenoid air valves of each array in the desired
pattern sequence, a colored pattern of dye is placed on the substrate
during its passage under the respective array.
Figures 3 through 7 depict end views, in partial or full section, of
the arrays 26 of Figures 1 and 2 which are equipped with the invention
disclosed herein. Individual support beams 102 for each array 26 extend
across conveyor 14 and are attached at each end to diagonal frame members
24. Perpendicularly affixed at spaced locations along individual support
beams 102 are plate-like mounting brackets 104, which provide support for
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primary dye manifold assembly 36 and associated apparatus, primary dye
collection chamber 80 and associated apparatus, and the apparatus
associated with the instant invention. In a preferred embodiment, valve
boxes 10n, supported by beams 102, may be used to house collectively the
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plurality of individual valves V, as well as the air manifold 74 associated
with each array.
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As depicted most clearly in Figures 4 through 7, primary dye manifold
assembly 36 is comprised of a pipe having a flat mating surface which ...
accommodates a corresponding mating surface on sub-manifold assembly 40.
` 10 Sub-manifold assembly 40 is comprised of sub-manifold module section 42,
grooved dye outlet module 50, and an elongate sub-manifold 46 cooperatively
formed by elongate mating channels in sub-manifold section 42 and outlet
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module 50. Sub-manifold module 42 is attached to primary dye manifold
~ assembly 36 by bolts ~not shown) or other suitable means so that drilled
; 15 outlet conduits 37 in the mating surface of manifold assembly 36 and
corresponding drilled passages 44 in the mating surface of sub-manifold
module section 42 are a1igned, thereby permitting pressurized liquid dye to
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flow from the interior of manifold assembly 36 to elongate sub-manifold 46.
: Associated with the mating face of dye outlet module 50 are a plurality
of grooves or channels 51 which, when dye outlet module 50 is mated to
sub-manifold module 42 as by bolts or other appropriate means (not shown),
form dye passage outlets 52 through which uniform quantities of liquid dye
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from sub-manifold 46 may be directed onto the substrate in the form of
aligned, parallel streams. The relative position or alignment of dye
channels 51 with respect to primary dye collector plate 84 and collector
plate support member 86 may be adiusted by appropriate rotation of jacking
screws 106 associated with mounting brackets 104.
Associated with dye outlet module 50 is deflecting air jet assembly 60,
shown most clearly in Figure 6, by which individual streams of air from air
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tubes 62 may be selectively directed, via an array of valves in valve box
100 and connecting supply conduits 64, across the path of respective dye
streams. Assembly 60 is comprised of an air supply tube support plate 66
and air tube clamp 68, intended to align and secure individual air
deflecting tubes 62 immediately outside dye outlets 52. By rotating air
tube clamp screw 67, the pressure exerted by clamp 68 on air tubes 62 may
be adjusted. Airfoil 72, positioned generally opposite air tubes 62, is
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~ intended to reduce the degree of turbulence within the region of the array
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due to the action of the transverse air streams lssuing from tubes 62.
Although not shown, the protruding portion of dye outlet module 50 against
which air tube clamp 68 urges tubes 62 is preferably configured with a
series of vee-shaped notches into which tubes 62 may partially be recessed.
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Further details of a similar alignment arrangement may be found in commonly
assigned U.S. Patent No. 4,309,881.
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Also associated with dye outlet module 50 is dye by-pass manifold 56
and by-pass manifold conduit 54, shown most clearly in Figure 5, which
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collectively act as a pressure ballast and provides for a uniformly
` pressurized dye supply within sub-manifold 46.
When the liauid dye stream is deflected, the liquid dye exiting from
dye passage outlets 52 is directed into primary dye collector chamber 80,
which may be formed of suitable sheet material such as stainless steel and
extends along the length of the array 26. Associated with collection
chamber 80 is a primary dye collector plate 84 which is comprised of a thin
flexible blade-like member which is positioned parallel and closely
adjacent to dye passage outlets 52. Primary collector plate 84 may be
adjustably attached at spaced locations along its length, as by bolt and
spacer means 85, to wedge-shaped elongate collector plate support member
`~ 86, which forms an extension of the floor of primary collection chamber 80
' and which is sharpened along the edge nearest the outlets 52 of dye
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~ discharge channels 51 and extends along the length of array 26. Any
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suitable adjustment means by which a thin, blade-like collector plate 84
may be mounted under tension along its length and aligned with the axes of
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dye outlet module grooves 51 may be employed; one such means is disclosed
in commonly assigned U.SO Patent No. 4,202,189.
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` As shown in Figure 5, primary dye collection chamber 80 is positioned
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generally opposite the array of air deflection tubes 62 for the purpose of
collecting liquid dye which has been diverted from the dye streams by the
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' transverse air stream from tubes 62. Primary dye collection chamber 80
also captures and collects partially diverted water sprayed at high
pressure from manifold assembly 36, as well as water sprayed from staggered
cleaning water nozzles 96 associated wtth wash water manifold 94, whenever
' the array is cleaned, e.g., when use of a different color dye is to be
' used. Primary dye collection chamber 80 may be attached by conventional
means to mounting brackets 104 as well as to sharpened collector plate
support member 86, which may be rabbeted to accommodate the floor of
chamber B0, as shown, and forms a cavity into which dye or wash water may
; be collected and removed from the interior of the array via primary dye
collection conduit 82. Mist shield 90, which generally extends the length
. 20 of the array, is attached to the bottom of the valve box 100 using bolts or
other suitable means, not shown. Shield 90 prevents wash water or dye,
either in the form of droplets or airborne mist, from traveling between the
manifold 36 and the valve box 100 and dripping onto and staining the
substrate from that side of the array. Mist shield 92, also attached to
valve box 100, uses spring force to compress elastomeric seal 93 which is
attached to the dye collection chamber 80. Shield 92 and seal 93 prevent
wash water, prlmarily in the form of airborne mist, from exiting the top of
the dye collection chamber 80 and settling onto the substrate below. Both
shields 90 and 92 and dye collection chamber 80 are preferably open at both
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ends so as to allow the pressurized air from air deflection tubes 62 to
escape without undue restriction.
-~ A principal component of the instant invention, secondary drain tray
110 extends along the length of primary dye collection chamber tray 80 and
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is attached thereto by means of hinge 112, which allows secondary drain
tray 110 to swing away from the underside of array 26 for occasional
cleaning and maintenance. When in position under array 26, secondary drain
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tray 110 may be secured through apertures (shown in Figure 7) in the
underside of tray 110 which are aligned with corresponding holes (not
shown) in the primary dye collection chamber 80 by means of bolts or other
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suitable means, not shown. A fixed distance is held between the secondary
drain tray 110 and primary dye collection chamber 80 through use of
spacers. Liqufd collected by secondary drain tray 110 may be collected by
gravity and discharged through drain pipe 114, as indicated in Figure 5.
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This liquid is transported through a suitable conduit to a waste water
drain.
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Associated with the unhinged end of secondary drain tray 110 is movable
shutter or shield 120, which is comprised of a thin elongate plate to
i which, in a preferred embodiment, tension is applied in a lengthwise
direction in order to reduce sag and assure proper alignment a~d fit. Such
tension may be introduced by a series of spring washers, as shown at 124 in
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Figure 10, similar to the means by which collector plate 84 may be
tensioned. As best shown in Figure 6, shield 120 is positioned to move
freely within the elongate gap 121 between the inside surface of secondary
drain tray 110 and the lower surface of primary dye collector plate support
member 86. When in an extended position, as when a cleaning operation is
- underway, the leading edge of shield 120 abuts tubular seal 70 in
liquid-tight association. Seal 70 may be affixed to air tube support plate
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66 via seal bracket 69, and air tube clamp screw 67. The trailing edge of
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shield 120 remains within gap 121 to an extent sufficient to assure that
:...................... liquid flowing along the surface of shield 120 and under collector plate
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. support member 86 towards the trailing edge of shield 120 must continue to
flow within gap 121 and along the inside surface of secondary drain tray
110 toward hinge 112, and not flow between shield 120 and tray 110 and
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t thereby onto the substrate 12. When the cleaning operation is completed
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and liquid dye is again to be directed onto the substrate, shield 120 is
moved to a position substantially totally within gap 121 formed by the
:.: inside surface of secondary drain tray 110 and collector plate support
. 10 member 86, as depicted in the left hand array of Figures 3 and 4.
.. ; As best shown in Figures 9 and 10, shield 120 extends under the side
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portions 80A of primary dye collection chamber 80, under a wear plate 128,
. and under shield shuttle 130, which contains an internal chamber suitable
. for accommodating a stack of opposing Bellville-type spring washers 124
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surrounding a tensioning bolt 125. Tensioning bolt 125 also pass through
.. pressure plate 122, to which is attached the end-most portion of shield
,~ 120, via a conventional clamp and screw arrangement shown generally at 126.
'~ This configuration provides for the controlled application of tension on
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.~ shield 120 by the compression of washers 124, and also couples shield 120
to moveable shuttle 130. When shuttle 130 is driven along the,.length of
.~ rotating shuttle guide threaded shaft 132, as described in more detail
. below, shield 120 is constrained to follow, without change in the tension
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.~ applied to shield 120.
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. The means by which shield 120 may be reversibly and reliably moved from
a "closed" to an "open" position (and vice versa) without skewing is best
described with reference to Figures 3, 9, and 11. At each outside end of
. array 26, shield 120 is attached to a moveable shuttle 130 which is
associated with shuttle guide threaded shaft 132, which extends alongside
array 26 in a direction generally aligned with conveyor 14 within the
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~ region of dye outlets 52. Shuttle guide shaft 132 is supported at one end
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; by shaft support plate and bearing 134 which allows for the free rotation
of shaft 132 The opposite end of shuttle guide shaft 132 is supported by
, a gear box 140. Both shaft support plate 134 and gearbox 140 are
permanently attached to gearbox mounting plate 135 which, in turn, is
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adjustably attached with bolts 136 to the end plates 80A of the primary dye
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` collection chamber 80. If desired, a bellows or similar sleeve may be used
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to protect threaded shaft 132 from dirt, dyestuffs or other contaminants.
. The gearboxes 140 on either side of the dye collection chamber 80 are
connected together by a conventional flexible drive shaft assembly as
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` better shown in Figures 7, 8, 9, and 11. The flexible drive shaft assembly
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consists of a spirally wound inner steel core 146 which rotates within and
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is protected by an impermeable casing 145. The steel core is rigidly
attached at both ends to shaft couplings 144 and 144a. The flexible drive
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shaft assembly is supported near its midpoint by shaft alignment collar
147. As seen in Figure 11, motor 160 is directly connected to rigid drive
shaft 142 to which is also connected worm 141. Rotation~of the motor 160
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imparts a direct rotation of worm 141 which in turn drives worm gear 143
with a corresponding fixed speed reduction. Worm gear 143 is directly
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attached to the shuttle guide threaded shaft 132. The torque pf motor 160
may therefore be enhanced by the combined mechanical advantages imparted by
; the worm gearing and the screw threads on threaded shaft 132, which threads
serve to drive shuttle 130 (and shield 120) in the desired linear
direction. Through the connection offered by the flexible drive shaft
assembly, the gearboxes on each side of the array 26 are constrained to
rotate in unison, which, in turn, synchronously propels the shuttle 130 on
each side of the array in the direction appropriate to the direction of
guide shaft 132 rotation. A particular advantage of this drive system is
- that it minimizes any skewing of the shield 120 due to movement of the ends
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of the shield 120 at different rates. A further advantage is the slow even
movement of the shuttle 130 which does not impart vibration or shock to the
sensitive dye manifold assembly.
Reversible motor 160 may use any appropriate type of drive; a pneumatic
motor has been found to be particularly satisfactory in terms of size and
reliability.
As depicted in Figure 9, a set of inductive proximity switches 131 or
the like may be adjustably positioned to detect the arrival of shuttle 130
at the desired end points of travel, and to disengage motor 160 as
appropriate. Connecting proximity switches 131 and motor 160 to pattern
control device 20 allows pattern control device 20 to sense the position of
shield 120. It is intended, using such switches 131, that the motion of
shield 120 may be controlled (i.e., both initiated and terminated) in
response to the pattern data from pattern control device 20, as
appropriate, thereby providing for the automatic cleaning/color changing of
arrays which are no longer needed to produce a given pattern, in
preparation for the production of a different pattern. The details of
automatically and electronically changing from one pattern to another is
set forth in U.S. Patent Number 4,170,883, issued October 16, 1979.
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