Claims:We Claim:

1. A print transfer paper drive system for synchronizing transfer-paper take-up Speed with a yarns Sheet comprising a transfer rollers (101) for advancing a print-transfer paper (P) carrying a design pattern from a reel (11), a guide roller (102) located downstream to the transfer rollers (101) that brings the print-transfer paper (P) in to the contact with the sheet of warp yarn (Y) unwound from a warp beam (12), a drag roller (103) located downstream to guide roller (102) that advances the exhausted print-transfer-paper (P’) running from the guider roller (102) to a take-up roller (104);

Characterized in that, said drag roller (103) and said take-up roller (104) are drivably connected with motors (103a, 104a) through gear boxes (103b, 104b) respectively;

Said motors (103a, 104a) are controllably connected with drives (103c, 104c) respectively;

a yarn-sheet-speed-feedback device (106) that is physically engaged with the warp yarn sheet (Y) to monitors warp yarn sheet speed;

and a controller (105) that communicates signals to the drive (103c, 104c) for controlling the speed of the drag roller (103) and the take-up roller (104).

2. The print transfer paper drive system for synchronizing transfer-paper take-up speed with yarns sheet as claimed in claim 1, wherein a sensor is arranged that continuously monitors diameter of the take-up-roller (104) during the accumulation of the exhausted paper (P’) on the take-up-roll (104) and provides feedback of the take-up-roller-diameter to the machine Controller (105).

3. A process for synchronizing the transfer-paper take-up speed with the speed of warp yarn sheet comprising following steps:

(a) unwinding the sheet of parallel warp yarns (Y) from the warp beam (12);
(b) unwinding the print-transfer-paper (P) from the reel (11) running against the sheet of warp yarns (Y) to direct the sheet of the transfer paper (P) carrying the dye design towards the lap of warp yarns (Y), and simultaneously transferring this design onto the warp yarns (Y) under the continuous effect of pressure through a heating pad;
(c) receiving the exhausted print-transfer paper (P’) onto the take-up roller (104);

Characterized in that,

(d) monitoring the warp yarn sheet speed by the yarn-sheet-speed-feedback device (106) and providing the yarn-sheet motion/speed data to the machine controller (105);
(e) continuously monitoring the diameter of the take-up roller (104) through the sensor (107) and providing the data to the machine controller (105);
(f) interpreting the yarn-sheet motion/speed data and the take-up-roller-diameter feedback device (sensor) (107) output data and providing the appropriate control signal to the Take-Up-roller-drive (104c);
(g) running the electric motor (104a) through the Take-Up-roller-drive (104c) to synchronize the speed of the take-up roller (104) with speed of the lap of warp yarn (Y);
(h) simultaneously providing a control signal to the drag roller motor drive (103c) through the machine controller (105) to set the speed of the motor (103a) to synchronize the paper Drag roller speed with that of the yarn-sheet speed.

Dated this on 28th April, 2020.
, Description:
FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION: Print-Transfer-Paper Drive System for Synchronizing Transfer-Paper Take-up Speed with Yarns Sheet and Process thereof
2. APPLICANTS:

(a) Name : PRASANT GAMATEX PRIVATE LIMITED
(b) Nationality : India
(c) Address : PLOT NO.: 4/A-1, PHASE-1,
G.I.D.C. ESTATE,
VATVA, AHMEDABAD- 382445,
GUJARAT, INDIA.



PROVISIONAL

The following specification describes the invention. þ COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION

The present invention relates to a system for transfer printing a design on warp yarns in a warp and weft fabric by applying a roll of transfer paper carrying a dye design to a moving web of warp yarn and more particularly it relates to an improved print-transfer paper drive system that synchronize the transfer-paper take up speed with the speed of sheet of warp yarn during warp yarn printing for woven fabric.

BACKGROUND OF THE INVENTION

In the past, attempts have been made to incorporate printed patterns into woven fabrics. In particular, attempts have been made to produce a fabric containing a printed design in combination with a woven design. Having the capability of combining a printed design with a woven design offers the ability to produce fabrics containing many different patterns and colors that have a unique and distinctive appearance. Unfortunately, problems have been experienced in the past in being able to synchronize a printed design with a woven design. For instance, in many applications, it is difficult to print a design directly onto a preformed woven fabric, since many fabrics tend to have an uneven topography. Also, the prior art has generally been deficient in providing a system for applying a printed pattern to a woven fabric that contains controls which maintain the printed pattern in alignment as it is applied to the fabric. Conventionally, these warp-printed fabrics have been obtained by means of the transfer-printing technique.
Fig. 1 shows a conventional paper drive roller system for driving print transfer paper and warp yarns during the warp printing. Fig.1 gives an overview of the existing paper-roller drive system. The paper drive of the existing machines has two output locations, Drag roller (1) & take-up-roller (2). Drive/power to the two rollers is provided from one single electric motor (3). The input of the electric motor (3) is connected with the drive (8). The drive/power output of the electric motor (3) is split with the help of a specialized gearbox (4) which is connected to the Drag roller shaft. This gearbox (4) has two stages for input speed reduction. A long coupling (5) is connected to the output of the first stage of two stage reduction gearbox. The coupling (5) is connected to the input shaft of the gearbox (6). Output of the gearbox (6) is connected to the take-up roller (2) shaft to transmit the requisite power to the take-up roller to wind the consumed paper.

For given operating speed of the loom angular speed of Drag roller (1) will remain constant while that of take-up-roller (2) will be decreasing as its diameter builds up due accumulation of consumed paper on take-up-roll (2). The speed ratio between Drag roller (1) and Take-up-roller (2) is kept such that Angular speed of Take-up-roller will be to wind the consumed paper from its minimum buildup diameter. In order to wind consumed paper on take-up-roller at optimum tension, a manually operated torque-limiter (7) is an integral part of gearbox (6).

The above described arrangement, though adequate, has a number of short comings. First, the setting of the torque limit on the second gearbox (6) is manual and subjective. The torque limit setting depends on the skill and experience of the operator. Too high a torque limit will tear the paper and the machine will have to be stopped to reset the whole process. This is costly from the point of lost production and its effect on the quality of the finished fabric. Also, as the paper roll diameter increases it is advisable to adjust the torque limit. This is not possible without stopping the machine. Additionally, the torque limiter, which is essentially a friction-brake, changes its operational characteristics with the attendant wear which is continuous due to the nature of the overall operational requirement. Finally, the non-standard (specialized) nature of the two gearboxes also makes its ready availability an issue resulting in long breakdowns in cases of gearbox failure due to whatever reason. And finally, there is no feedback of the actual speed of the yarn-sheet to integrate with and control the speed of the transfer-paper and make self-correcting adjustments to synchronize the yarn-sheet and loom-printer speeds. This has to be managed manually and has attendant drawbacks of delayed response from the operator and its effect on the quality of the output.

In light of the above drawbacks with conventional systems, it is apparent that there is a need to develop a system to solve afore-mentioned problem.

OBJECT OF THE INVENTION

The main object of the present invention is to recognize and address the foregoing disadvantages, and other disadvantages of prior art constructions and methods.

Another object of the present invention is to provide an improved print-transfer paper drive system for forming woven fabric that synchronize the transfer-paper take up speed with the speed of sheet of warp yarn during warp yarn printing.

Further object of the present invention is to provide an improved print-transfer paper drive system for forming woven fabric that render enhanced control over the whole printing process and improve reliability and maintainability of the drive system.

Yet another object of the present invention is to provide an improved print-transfer paper drive system wherein the encoder provides feedback of the length of the yarn-sheet that passes through the printer. This information can be combined with the movement of the paper and the paper can be moved in synchronous mode, a-synchronous mode or a combination of synchronous & a-synchronous modes to create various printing effects by varying the dye deposition density. This additional capability can be creatively utilized to generate a variety of unique printing effects of the finished cloth which are otherwise not feasible.

SUMMARY OF THE INVENTION:

The present invention relates to a print-transfer paper drive system that synchronize the transfer-paper take up speed with the speed of sheet of warp yarn during warp yarn printing for woven fabric. In present invention, the drag roller and the take-up roller are provided with independent motor, drive and gearbox assembly. In order to synchronize the print-transfer paper take up speed of the take-up roller and the drag roller with the speed of yarn sheet, the controller receives the data of diameter of the take-up roller and the yarns sheet speed through the sensor and the yarn sheet speed feedback device respectively, and accordingly the controller send signals to the drives to control the speed of respective motor which in turn control the speed of take-up roller and the drag roller to synchronize the with the speed of the yarn sheet.

BRIEF DESCRIPTION OF THE INVENTION:

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:

Fig. 1 shows a schematic view of the conventional paper roller drive system.

Fig. 2 shows a print-transfer-paper path for the loom printer through the paper roller drive system according to present invention.

Fig. 3 shows an improved paper roller drive system according to present invention.

DETAILED DESCRIPTION OF THE INVENTION

The nature of the invention and the manner in which it works is clearly described in the provisional specification. The invention has various embodiments and they are clearly described in the following pages of the provisional specification. Before explaining the present invention, it is to be understood that the invention is not limited in its application.

In the description, the term "loom" or "warp loom" embraces both weaving looms themselves, that is to say warp and weft looms. Likewise, by "dye design" is meant not only a design obtained from one or more dyes, but also a plain print.

The present invention is carried out on a conventional loom equipped with components allowing a heat treatment to be carried out on the warp yarns while they are being tensioned by the fabric take-up roller of the loom. Such a loom also comprises particular arrangements allowing the characteristic cloth of the invention to be produced.

In general, the present invention is directed to a continuous multi colored printing for yarn during weaving on high speed looms. The present invention discloses an improved print-transfer-paper technique on a continuously advancing lap of warp yarns on a weaving loom. The proposed print-transfer-paper drive system enables the print-transfer paper carrying suitable dye design unwinding from the reel is brought into the contact with the sheet of warp yarn by synchronizing a paper take up speed with the speed of warp yarn sheet. Now, as directed in Fig. 2, a loom has, in the direction of run of the yarn, a warp beam (12) which is mounted on a shaft and on which all the parallel warp yarns are wounded.

Now, in Fig. 2 and 3, one embodiment of an improved print-transfer-paper drive system (100) according to present invention is illustrated. Now as shown in Fig. 2, the print-transfer-paper drive system (100) advances a print-transfer paper (P) from a reel (11) running against the sheet of warp yarns (Y) to direct the sheet of the transfer paper (P) carrying the dye design towards the sheet of warp yarns (Y), and simultaneously transferring this design onto the sheet of the warp yarns (Y) under the continuous effect of pressure.

Referring continuous to Fig. 2, the print-transfer-paper drive system (100) according to present invention comprises transfer rollers (101) for advancing a print-transfer-paper (P) carrying a suitable pattern from the reel (11), a guide roller (102) located downstream to the transfer rollers (101) that brings the print-transfer paper (P) in to the contact with the sheet of warp yarn (Y), a drag roller (103) located downstream to the guide roller (102) that advances the exhausted print-transfer-paper (P’) running from the guide roller (102) to a take-up roller (104), a controller (105). The exhausted paper (P’) back to be received on the take-up roller (104). A profiled heating pad (not shown) arranged in the proximity of the guide roller (102) keeps the print-transfer-paper (P) permanently pressed against the sheet of warp yarns (Y) during printing operation.

It is to be understood that the term “paper take-up speed” imply as the rotating speed of the take-up roller (104) to wound the exhausted-print paper (P’).

Further, the system according to present invention also includes a yarn-sheet-speed-feedback device (106) that is physically engaged with the warp yarn sheet (Y) to monitors warp yarn sheet speed. This eliminates all other requirements of engaging the loom-printer with the loom or its control system and still provides a robust – accurate and reliable - synchronizing link to maintain the required speed synchronization which ensures the desired printing results.

Now as show in Fig. 3, drives/power to the two paper rolls, viz. the drag roller (103) and the take-up-roller (104), are provided by two independent electric motors (103a, 104a) respectively. The motor output is connected to the respective rollers (103, 104) through appropriate gear boxes (103b, 104b) respectively. This configuration eliminates the need for any physical link between the two roller drives to distribute drive/power to the two rollers. Both the motors (103a, 104a) are managed by their independent drives (103c, 104c). Further, a sensor (107) is arranged that continuously monitors diameter of the take-up-roller (104) during the accumulation of an exhausted paper (P’) on the take-up-roll (104) and provides feedback of the take-up-roller-diameter to the machine Controller (105).

During the warp yarn printing process, the sheet of parallel warp yarns (Y) is continuously unwound from a warp beam (12) in a known way. During travelling of the sheet of warp yarn (Y) from the beam (12), the travelling print-transfer paper (P) is continuously pressed against said sheet of warp yarns (Y), while said sheet of warp yarns (Y) and said print-transfer paper (P) are travelling in a speed ratio and in proximity to one another, care being taken to direct the travelling transfer paper (P) carrying the dye design towards the lap of warp yarns (Y), while simultaneously transferring said dye design from said transfer paper (P) onto said warp yarns (Y) by virtue of said continuous pressure and of dry heat. After printing process, the exhausted-print paper (P’) is continuously wound on the rotating take-up roller (104).

Now for synchronizing the exhausted-print paper take up speed with the warp yarn sheet speed, the rotating speed of the take-up roller (104) and the drag roller (103) is synchronized with the warp yarn sheet speed. For that, the yarn-sheet-speed-feedback device (106) is continuously engaged with the sheet of warp yarn (Y) and provides the yarn-sheet motion/speed data to the machine controller (105). The machine Controller (105) in turn interprets this data along with the feedback of the take-up-roller-diameter feedback device (sensor) (107) output data, and provides the appropriate control signal to the Take-Up-roller-drive (104c) to run the electric motor (104a) at appropriate speed. Said electric motor (104a) rotates the take-up roller (104) at the speed in synchronization to the speed of the sheet of warp yarn (Y). The controller (105) simultaneously provides an appropriate control signal to the drag roller motor drive (103c) to set the speed of the motor (103a) to synchronize the paper Drag roller speed with that of the yarn-sheet speed. Thus, the paper take-up speed of the take-up roller and the drag roller are synchronized with the warp yarn sheet speed.

Thus, both setting of the transfer-paper speed, synchronization of the speeds of the two rollers with the yarn-sheet, and continuous adjustment of the loom-printer paper speed are now fully automated; and all these operational parameters are managed optimally without any operator intervention. Moreover, various printing effects can be derived by appropriate synchronization of the yarn-sheet/paper speeds just by adjusting related operating parameters on the controller (105) itself, even on-the-fly. Additionally, these advantages are derived without any requirement of connecting the loom-printer operational mechanisms with any aspect of the loom.

The invention has been explained in relation to specific embodiment. It is inferred that the foregoing description is only illustrative of the present invention and it is not intended that the invention be limited or restrictive thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. The scope of the invention should therefore be determined not with reference to the above description but should be determined with reference to claims along with full scope of equivalents to which such claims are entitled.