This invention relates to a process of conditioning of textile and other organic material through thermal treatment.
Organic composites, polymers, textile substance are made up of long molecular chains which are interconnected to chemical or atomic bonds. The physical properties, mostly strength and elongation of these molecular chains or linear fibres depends upon the inter molecular bonding and also on the radial frictional forces exerted on the fibre during spinning process.
The presence of moisture within the fibre vastly determines the strength of the individual fibre and also plays a vital role on the inter fibre friction.
Inter fibre friction is depended on radial force acting on the fibre. Radial forces are induced at the time of spinning the yarn. Proper thermal treatment would result in increase or decrease of these radial force which would in turn determine the fibre friction and finally strength of the yarn.
Therefore this invention is to carry out a special treatment to the textile fibre in the form of yarn or fabric to simultaneously impart the required optimum moisture and also to perform thermal treatment, thereby making the material exhibit its optimum strength, elongation, dye affinity etc.. The process is developed by analysis of different fibres and their actual moisture content at the time of manufacture and the changes in the physical form during manufacturing process. The process parameters are fine tuned depending upon the type of material.
a) The invention contains the dual chamber steam generation system. The dual chamber is incorporated to ensure that water required for treatment is placed in the secondary chamber at the time of creation of vacuum. This would result in higher degrees of vacuum thereby resulting in production of cold saturated steam at temperature closer to ambient. In this invention the flow of water from main

vessel to the dual chamber is by means of gravity and the flow of water from the secondary chamber to the main vessel is by means of suction.
b) V.A.BOOSTER :
This system enriches the inlet air let inside the vessel with saturated steam, thereby maintaining saturated conditions within the main vessel
c) Variable speed drive for the vacuum pump would result in creation of higher levels of vacuum at faster rate.
d) Capillary mechanism within the water chamber would increase the surface area of water in contact with evacuated atmosphere, enabling faster rate of production of saturated steam.
YARN CONDITIONING PROCESS : Yarn conditioning process is invented for the treatment of yarn with saturated steam exactly in accordance to the vacuum pressure curve of water.
It is imperative that the material under treatment is always treated with saturated steam of the same temperature as that of the material. The difference in temperature of steam and material would result in thermal imbalance thereby converting the steam to wet steam which would damage the material. The process is carried out, below atmospheric pressure where saturated steam is generated by spontaneous evaporation at low temperatures by various methods as described later.
High degree of vacuum is essential to ensure penetration of saturated steam homogenously throughout the material. Impregnation of saturated steam is carried out in several phases depending upon the size of material or bulk density of the material subject to treatment.

BRIEF DESCRIPTION OF DRAWING :
The basic plant consist of a cuboidal vessel called YCP shell marked - which is made of stainless steel. The cuboidal shell is capable of withstanding high vacuum. This shell is completely insulated to avoid condensation and to improve the efficiency of treatment. The vessel is closed in front by a flat rectangular lid which can be moved by a sliding mechanism with the geared motor arrangement.
The door opens and closes to ensure entry and exit of material to be treated. The vessel is connected to vacuum pump which can create vacuum to the required degree. Vacuum pump is connected to a motor and the speed of which can be varied. The vessel is connected to a water receiver which is kept below the level of the vessel The bottom of the YCP vessel has a chamber containing a heating apparatus which can heat the water to required temperatures. The flow of water from the water receiver to the vessel is by suction in the flow of water and from the YCP vessel to the receiver is by gravity. The vessel and the receiver are connected by means of valve. The receiver is also connected to the atmosphere by means of a valve.
Capillary arrangement inside the bottom of the vessel is placed to increase the surface area of water incident to the evacuated inner atmosphere of the YCP vessel.
The Turbo charger mechanism is connected to the vessel through a valve. The entry of air inside the vessel is through this Turbo charger mechanism. The Turbo charger mechanism contains the inverted atomised sprayer, finned air heater, pressure and temperature sensors.
The level of water in the vessel is monitored by level sensor. Water receiver is connected to heat exchanger which would cool the water to required temperatures. Water chamber of the vessel is connected to dosings, port dosing pump which

would dos enzymes, dye absorption, catalyst, friction reducing coils, etc., from time to time as required in the final treatment.
The vessel is connected with temperature sensor, pressure sensors, humidity sensor. The physical changes of vacuum , temperature, door and material ,etc., are monitored by sensors. Operation of pumps and valves are through pneumatics and the signals are processed by central microprocessor system to carry out the entire process. The process parameters are fine-tuned for different types of material and stored in the menu. Selection of pre menu would enable micro processor to carry out the process exactly in accordance with the stored parameters.
DETAILED DESCRIPTION OF THE INVENTION :
The process of yarn conditioning starts by loading materials like yarn, fibre on suitable trolleys. The trolleys are placed inside the vessel by automatic loading platform or manually. The pegs or cross supports of trolley are made modular and adjustable, so that depending on the size of the material it may adjusted on sides. The material placed on the trolleys is pushed inside the vessel. Door of the vessel is closed by electro mechanical system. The vessel door is sealed using gasket seal and pneumatic sealing arrangement.
Water required for conditioning is initially present in the receiver. Vacuum pump is switched on and all the valves are closed but for the valve connecting the main vessel of the vacuum pump. The speed of the vacuum pump is varied progressively during the course of creation of vacuum. The speed is increased proportionately when vacuum is created. After adequate vacuum is created. Vacuum valve is closed.
To start the conditioning process, water is required. Since the receiver is kept at a level lower than the level of the water chamber in the main vessel. Valve VEA(ambient) is opened and vale VE is opened. The atmospheric pressure pushes

the water from the receiver through the valve VE ( Item No.14 in the drg.) inside the main vessel. As soon as the level of the water is reached, all valves are closed.
Heating system is switched on. Heating system may he electrical, steam or LPG fired system. Since water present in the main vessel is exposed to evacuated atmosphere inside the vessel, water starts evaporating at lower temperature in accordance to vapour pressure curve of water. This generation of cold saturated steam is assisted by capillary mechanism which is kept in the water chamber. The capillary mechanism is sintered SS element kept in an array over the surface of water. This increases the surface area exposed for evaporation. The temperature of the system is increased gradually depending on the type of material. This cold saturated steam generated is absorbed by the textile material kept within the vessel. Evacuated atmosphere also assists impregnation of saturated steam not only within the yarn but also within the fibres.
Depending on the package size and density of package, the temperature and
pressure varies.
Once a certain degree of temperature is attained, the temperature of the material is maintained at the attained temperature for a predetermined dwell time to allow impregnation ,
The process of evacuation and impregnation is one cycle. This cycle is carried several times.
To recreate vacuum for the second cycle, the water from the main vessel has to be take to the receiver. To enable this, all valves are closed, Valve VE is open. Compensation valve is also opened, there by allowing water from the main vessel to flow to the receiver by gravity.

Now all valves are closed and vacuum is switched on. Opening the valve W2, ( item 2 in the drg, ). The process of conditioning is carried out once again at evacuated temperature of around 20% more than the initial temperature.
The cycle of conditioning from evacuation to impregnation with saturated steam is repeated twice or 3 times depending upon the size of the cone, package or the fabric roll.
After repeated cycles of conditioning is completed, the VA Booster system is activated. External air is allowed to the inside main vessel to elevate the pressure from vacuum to atmospheric pressure, so that the material can be taken out. The air left inside the vessel is charged with saturated steam through the VA Booster system. VA Booster system has a high pressure automised inverted spray. Air taken inside this tunnel is initially heated using finned air heaters. Temperature of hot air is maintained equal to the temperature of the inside atmosphere of the vessel. This hot air absorbs the moisture from the automised spray and thereby saturates itself with water vapour.
This saturated air is allowed to get inside the main vessel and also inside the textile materials. Once the pressure inside the vessel comes to atmospheric pressure VA Booster system is cut off. The door is open and the material is taken out. The material taken out is kept in room temperature for stablisation for a short period, depending upon the type of material. After stabilization is over, material is packed and sent for subsequent processing.
STEP 1 : Yarn or textile material in the final form is placed on the yam carrier. Yarn carriers are placed inside the yarn Conditioning Plant either manually or through automatic platform.
STEP 2 : The door is closed

STEP 13: Heating system switch on to achieve temperature T2
STEP 14 : Material kept in dwell at this temperature.
Note : Depending upon the package size and bulk density.
STEP 15 : Cycle repeated, in case of very large packages thrice or 4times,
STEP 16 : VA heating element on , VA valve on, VA automiser on
STEP 17 : Temperature and pressure in VA monitored in accordance to curve VA temperature and VA heating elements off when temperature is achieved.
STEP 18 : VA valve remains open until atmospheric pressure is achieved inside the vessel.
Process completed. Material is taken out the chamber.

I CLAIM : -
1. An invention relating to a process for conditioning of yarns, textile and other organic material through thermal treatment with saturated steam within a cuboidal shell shaped insulated vessel connected to a vacuum pump for generating vacuum which inturn is connected to a water receiver.
2. An invention as claim in claim 1 above wherein the apparatus has a turbo charging VA booster mechanism for entry of air inside the vessel. The turbo charger has a temperature and pressure controller mechanism to maintain saturation levels of air taken inside the vessel. It also contains a atomiser spray within finned air heater and inlet air microbial filter.
3. An invention as claimed in claim 1 above wherein the apparatus has cooling arrangement for the water receiver to ensure that water is cooled before every process. This ensures that the process starts from ambient temperature every time and continues on the vapour pressure curve.
4. An invention as claimed in claim 1 above wherein the apparatus has receiver which is kept below the height of the main vessel allowing flow of liquid by gravity from the vessel to receiver and by suction from the receiver to the vessel.
5. An invention as claimed in claim 1 above wherein the apparatus has a capillary system within the chamber of the vessel to increase the surface area of evaporation. Minimum of 3000 sq. mm is provided for every gram of material processed.

6. An invention as claimed in claim 1 wherein the apparatus has water chamber within the vessel which would have a quantity of water up to a maximum of 300 cc of Kg of yarn conditioned.
7. An invention as claimed in claim 1 above wherein the process parameters are fine tuned for different types of yarn and varies between 55°C to 150°C depending upon the types of yarn.
8. An invention as claimed in claim 1 above wherein the vacuum pump connected to the vessel is rotated by means of motor. The speed of the motor is changed depending upon the vacuum created. The speed of the vacuum pump is increased in stages during creation of vacuum.
9. An invention as claimed in claim 1 wherein the insulated vessel is connected to temperature sensor, pressure sensor and humidity sensor.
10. An invention as claimed in claim 1 above wherein yarn placed on trolleys is subjected to water and heat which evaporates the water present at lower pressure and temperature resulting in generation of cold saturated steam.
11. An invention as claimed in claim 1 above wherein the process of evacuation and impregnation of saturated steam takes place within the fibres in accordance to vapour pressure curve of water.
12. An invention as claimed in claim 1 above wherein the yarn conditioning vessel is a fully automated vessel and is designed to withstand high degree of vacuum. The process of conditioning is by saturated steam in accordance to vapour pressure curve of water.

13. An invention as claimed in claim 1 above wherein the apparatus has process
parameters, fine tuned depending upon the yarn which is selectable through
menu.
14. An invention as claimed in claim 1 above wherein the apparatus consists of
loading mechanism to load the material inside the chamber and to remove
the material outside the chamber.
15. An invention as claimed in claim 1 above wherein the process of evacuation
and impregnation is carried out for a minimum of 2 times and a maximum of
5 times depending upon the package size.
Dated this 25th' day of November 2000.