A polyester fabric continuous pad dyeing device and pad dyeing process

Abstract

The present application belongs to the field of textile printing and dyeing technology, and particularly relates to a polyester fabric continuous pad dyeing device and pad dyeing process, which comprises a pad dyeing frame; a feeding roller is arranged on one side of the top of the pad dyeing frame, and a tension roller is arranged below the feeding roller; through the design of a mixed turbulent flow component, the dye is delivered to the inner and outer rotating rods by a circulating pump to realize dye circulation; the fabric advances to drive the guide wheel to rotate, drives the first driving wheel and the first driven wheel, and makes the inner rotating rod rotate reversely; the spiral plate agitates the dye; at the same time, the motor drives the third driving wheel to drive the axial stirring rod to stir the dyeing liquid in the same direction; the outer rotating rod uniformly sprays the dye; the design of the staggered arrangement of the spiral plates, the liquid outlet holes and the diffusion holes further enhances the mixing effect; multiple components cooperate to stir the dye from multiple directions, avoids stratified precipitation, ensures uniform dye concentration, greatly improves the mixing efficiency compared with the traditional method, effectively solves the dyeing color difference problem, and significantly improves the dyeing uniformity and product quality.

Description

Technical Field

[0001] This invention belongs to the field of textile printing and dyeing technology, and particularly relates to a continuous pad dyeing device and pad dyeing process for polyester fabric. Background Technology

[0002] Polyester fabric, as a common synthetic fiber fabric, is widely used due to its excellent performance. In the textile industry, the main processes are spinning, weaving, and pad dyeing. The core function of pad dyeing is to ensure that the dye liquor penetrates and adheres evenly to the fabric, achieving uniform dyeing. In the pad dyeing process, the fabric is first immersed in the dye liquor, allowing the dye liquor to be fully absorbed on the surface and inside of the fabric. Then, the excess dye liquor is removed by the squeezing of rollers, controlling the amount of liquor on the fabric and ensuring uniform dyeing. The sizing layer formed by the warp yarns during the weaving process of polyester fabric will hinder the penetration of the dye liquor. Pad dyeing can achieve continuous production, is suitable for large-scale industrial production, and meets the large market demand for polyester fabric. Compared with traditional dyeing methods, it can effectively reduce production costs and improve production efficiency.

[0003] However, in the continuous pad dyeing process of polyester fabric, when the flat fabric moves in the straight dyeing tank, it separates the dye liquor into upper and lower layers, hindering the natural convection and mixing of the two sets of dye liquors. Moreover, in the laminar flow state of the straight dyeing tank, the dye liquor flows in parallel layers without sufficient disturbance. Under the combined effect of the physical barrier of the fabric and the laminar flow characteristics of the dye liquor, the dye liquor cannot be fully mixed, and the dye cannot penetrate evenly to all parts of the fabric. This results in a large difference in penetration between the edge and center of the fabric, causing obvious color difference, reducing product quality and pass rate. Secondly, because the traditional dyeing tank is set in a rectangular shape according to the movement characteristics of the fabric, dye particles, undissolved auxiliaries and other impurities in the dye liquor are easy to settle at the bottom of the tank. When the fabric passes through the bottom of the dyeing tank, these impurities will adhere to the surface of the fabric, causing defects such as color spots and color patches in the dyeing. In addition, due to the layering and reduced concentration of the dye liquor, the traditional process requires frequent replenishment of new dye liquor to maintain the dyeing effect. The continuous addition of new dye liquor not only increases the cost of dye, but the unused dye liquor will eventually be discharged with the wastewater, resulting in resource waste. Summary of the Invention

[0004] In view of this, the present invention aims to solve the technical problems of traditional continuous pad dyeing of polyester fabrics, such as difficulty in mixing dye liquor, easy stratification and precipitation, resulting in large color difference and defects in the fabric, as well as high dye cost and serious waste of resources.

[0005] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0006] This invention discloses a continuous dyeing apparatus for polyester fabrics, comprising:

[0007] Dyeing rack;

[0008] A feed roller is located on one side of the top of the dyeing rack, and a tension roller is located below the feed roller;

[0009] The rollers are symmetrically arranged on the other side of the dyeing rack;

[0010] The dye box is located below the dyeing rack and has an arc-shaped bottom.

[0011] There are four guide wheels, which are located at the bottom of the dye box to guide the fabric to move along a specific path inside the dye box. The bottom of the dye box is rotatably connected to the tail wheel.

[0012] A mixing turbulence component is disposed inside the dye tank for mixing the dyes within the dye tank;

[0013] A dye collection assembly is located at the bottom of the dye tank to collect excess dye.

[0014] Furthermore, the hybrid turbulence component includes:

[0015] The first drive wheel, which has at least four of them, is rotatably connected to the rear end of the dye box;

[0016] The first passive wheel is rotatably connected to the middle of the rear end of the dye box and meshes with the first active wheel;

[0017] An inner rotating rod is rotatably connected inside the dye box and fixedly connected to the first passive wheel;

[0018] Two spiral plates are arranged in a set and are symmetrically installed on the outside of the inner rotating rod.

[0019] The liquid outlet holes are symmetrically located inside the inner rotating rod and correspond one-to-one with the spiral plates.

[0020] A circulating pump is installed at the bottom front of the dye box, with its inlet connected to the bottom of the dye box and its outlet connected to the front of the inner rotating rod.

[0021] A radial tension assembly, located inside the dye chamber, is used to stretch the fabric entering the dye chamber.

[0022] Furthermore, the hybrid turbulence component also includes:

[0023] A rotating disk, which is rotatably connected to the outside of the front sealing cover;

[0024] The second passive wheel is fixedly connected to the front end of the rotating disk;

[0025] The third drive wheel is connected to the end of the dye box for rotation;

[0026] An axial stirring rod is mounted in a ring on a rotating disk;

[0027] An auxiliary outer wheel is installed inside the axial stirring rod;

[0028] The outer rotating rod is rotatably connected between the sealing covers located at the front and rear ends;

[0029] An auxiliary inner wheel is mounted on the front end of the outer rotating rod and meshes with the auxiliary outer wheel;

[0030] A liquid separator is fixedly connected inside the sealing cover at the front end. The inlet end of the liquid separator is connected to the outlet end of the circulating pump, and the outlet end of the liquid separator is connected to the inner rotating rod and the outer rotating rod respectively.

[0031] Furthermore, the outlet hole is located at the front end of the spiral plate, so that when the inner rotating rod rotates in the opposite direction, the dye flows along the shape of the spiral plate when it is discharged from the outlet hole.

[0032] Furthermore, each set of spiral plates is arranged in an alternating pattern on the inner rotating rod, so that the dye collides with the adjacent dye when the dye flows on the spiral plate.

[0033] Furthermore, the spiral plate has a diffusion hole at its edge away from the inner rotating rod.

[0034] Furthermore, the radial tension assembly includes:

[0035] Two sealing covers are provided and are symmetrically installed at the front and rear ends of the dye box. They are rotatably connected to the inner rotating rod and the guide wheel.

[0036] A radial box is installed inside a sealing cover, and a radial groove is provided between the radial box and the sealing cover;

[0037] A return spring is installed inside the radial housing;

[0038] The slide rail seat is connected to the radial groove of the radial box by a slide rail fit.

[0039] A radial roller, which is rotatably connected between the slide rail seats at the front and rear ends;

[0040] A radial rod, one end of which is fixedly connected inside the slide rail seat, and the other end of which slides through the outside of the radial box;

[0041] The cams are arranged in pairs and are rotatably connected inside the sealing cover and fixedly connected to the inner rotating rod.

[0042] Furthermore, the dye collection assembly includes:

[0043] A collection box is installed at the arc-shaped bottom of the dye box and is connected to the dye box. The top of the collection box has a linearly arranged conical groove, and the bottom of each set of conical grooves has a feed groove. The bottom of the collection box has a drain groove connected to the circulating pump, and the drain groove and the feed groove are connected.

[0044] A tip plate is installed inside the feed trough, with the tip of the tip plate positioned at the bottom of the conical groove.

[0045] Furthermore, a spiral limiting plate is installed inside the arc-shaped dye box.

[0046] A continuous pad-dyeing process for polyester fabrics, the specific steps of which are as follows:

[0047] First, the circulation pump starts working, extracting the dye from the bottom of the dye tank and dividing it into two parts through the separator. These parts are then transported to the inner and outer rotating rods respectively, providing a raw material circulation basis for subsequent dye mixing and dyeing, enabling the reuse of dye and reducing waste.

[0048] Second, the fabric is kept taut under the action of the feed roller and tension roller and enters the four guide wheels at the bottom of the dye box in an orderly manner. When the fabric moves around the guide wheels, the friction between them causes the guide wheels to rotate in the same direction, which in turn drives the first active wheel connected to it to rotate, providing power input for the mixing turbulence component.

[0049] Third, the rotation of the first driving wheel drives the rotation of the first driven wheel meshing with it. The first driven wheel is fixedly connected to the inner rotating rod, which in turn causes the inner rotating rod to rotate in the opposite direction. The spiral plate outside the inner rotating rod stirs the dye, and the dye flowing out of the outlet hole mixes with the original dye in the tank under the push of the spiral plate, spreading from the center of the dye tank to the surrounding area.

[0050] Fourth, the motor starts and drives the third active wheel to rotate in the reverse direction. Through meshing with the second passive wheel, it drives the rotating disk to rotate in the forward direction, so that the axial stirring rod installed on the rotating disk in a ring can stir the dye in the forward direction. At the same time, the axial stirring rod drives the outer rotating rod to rotate through the meshing transmission of the auxiliary outer wheel and the auxiliary inner wheel. The discharge hole of the outer rotating rod sprays the dye evenly on the outside of the fabric.

[0051] Fifth, the rotation of the inner rotating rod drives the cam that is fixedly connected to it to rotate. The irregular shape of the cam periodically squeezes the radial roller. When the cam protrusion contacts the radial roller, it pushes the slide rail seat to make centrifugal motion along the radial groove, so that the radial roller applies tension to the fabric to achieve stretching.

[0052] Sixth, the dye that settles to the bottom gathers at the lowest point under the action of gravity and flows into the collection box. The conical groove at the top of the collection box guides the dye into the feed trough, and the pointed plate reduces the flow resistance of the dye. Under the suction and pressure of the circulating pump, the dye is extracted through the drain trough and sent back to the dye box for recycling.

[0053] Seventh, the spiral limiting plate inside the arc-shaped dye box provides a specific spiral flow path for the dye settling at the bottom. When the axial stirring rod rotates and drives the dye liquor to flow, the dye settling at the bottom diffuses along the trajectory of the spiral limiting plate, collides and disperses with the surrounding dye liquor, and avoids accumulation at the bottom.

[0054] Compared with existing technologies, the continuous dyeing apparatus for polyester fabrics described in this invention has the following advantages:

[0055] 1. This invention utilizes a mixed turbulence component design. A circulating pump delivers dye to the inner and outer rotating rods, achieving dye circulation. The fabric's movement drives the guide wheel to rotate, which in turn drives the first active wheel and the first passive wheel, causing the inner rotating rod to rotate in the opposite direction. The spiral plate agitates the dye. Simultaneously, a motor drives the third active wheel, which in turn drives the axial stirring rod to agitate the dye liquor in the forward direction. The outer rotating rod evenly sprays the dye. The staggered arrangement of the spiral plates and the design of the outlet and diffusion holes further enhance the mixing effect. Multiple components work together to agitate the dye from multiple directions, avoiding stratification and sedimentation, ensuring uniform dye concentration. Compared to traditional methods, this significantly improves mixing efficiency, effectively solves the problem of color difference in dyeing, and significantly improves dyeing uniformity and product quality.

[0056] 2. This invention utilizes the arc-shaped design at the bottom of the dye tank, combined with the conical groove at the top of the collection tank, to guide the settled and excess dye to converge and flow into the collection tank. The pointed plate reduces the obstruction to dye flow. Under the action of the circulation pump, the dye is extracted through the drain tank and sent back to the dye tank for recycling, reducing dye waste and procurement costs. The spiral limiting plate promotes the homogenization of the settled dye, ensuring the stability of the circulation system. The recycling of dye reduces wastewater discharge, conforms to the concept of green production, and achieves both economic and environmental benefits.

[0057] 3. This invention utilizes a radial tension component design. An inner rotating rod drives a cam to periodically squeeze the radial roller, which in turn pushes the slide rail to dynamically stretch the fabric. This periodic action allows the fabric to fully unfold, increasing the contact area with the dye, promoting uniform dye penetration, and preventing uneven dyeing caused by wrinkles and stacking. In conjunction with the feed roller, this invention comprehensively optimizes fabric processing and improves dyeing quality. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0059] Figure 2 This is another schematic diagram of the overall structure of the present invention;

[0060] Figure 3 This is a plan view of the fabric movement according to the present invention;

[0061] Figure 4 This is a schematic diagram of the spiral plate of the present invention;

[0062] Figure 5 This is a dye flow direction indicator diagram of the present invention;

[0063] Figure 6 This is a schematic diagram of the dye box of the present invention;

[0064] Figure 7 This is a schematic diagram of the hybrid turbulence component of the present invention;

[0065] Figure 8 This is a schematic diagram of the sealing cover of the present invention;

[0066] Figure 9 This is a schematic diagram of the longitudinal section of the dye box of the present invention;

[0067] Figure 10 This is a schematic diagram of the radial tension component of the present invention;

[0068] Figure 11 This is a cross-sectional view of the dye collection assembly of the present invention.

[0069] The markings in the diagram are as follows:

[0070] 1. Dyeing rack; 11. Feed roller; 111. Tension roller; 12. Roller; 13. Dye box; 14. Guide roller;

[0071] 2. Mixing and Turbulence Components; 21. First Driving Wheel; 22. First Passive Wheel; 23. Inner Rotating Rod; 24. Spiral Plate; 241. Diffuser Hole; 25. Liquid Outlet Hole; 26. Circulating Pump; 211. Sealing Cover; 212. Radial Box; 213. Return Spring; 214. Slide Rail Seat; 215. Radial Roller; 216. Radial Rod; 217. Cam; 221. Rotating Disk; 222. Second Passive Wheel; 223. Third Driving Wheel; 224. Axial Stirring Rod; 225. Auxiliary Outer Wheel; 226. Outer Rotating Rod; 227. Auxiliary Inner Wheel; 228. Separator Pipe;

[0072] 3. Dye collection assembly; 31. Collection box; 311. Conical trough; 312. Feed trough; 313. Drainage trough; 32. Tip plate; 33. Spiral limiting plate. Detailed Implementation

[0073] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0074] See Figures 1-5 As shown, this invention provides a continuous pad-dyeing device for polyester fabric, including a pad-dyeing frame 1; a feed roller 11, disposed on one side of the top of the pad-dyeing frame 1, with a tension roller 111 below the feed roller 11. The combined design of the feed roller 11 and the tension roller 111 ensures that the polyester fabric maintains a stable tension during the feeding process, avoiding problems such as wrinkles and loosening of the fabric, and ensuring the continuity and stability of the continuous pad-dyeing process; a roller 12, symmetrically disposed on the other side of the pad-dyeing frame 1, which can uniformly squeeze the fabric, allowing the dye to fully penetrate into the interior of the polyester fabric fibers; and a dye box 13, disposed below the pad-dyeing frame 1, with an arc-shaped bottom. The shape and structure guide the dye to naturally gather at the bottom. Combined with the dye collection component 3 set at the bottom, it can efficiently collect excess dye, realize the recycling of dye, and greatly reduce dye waste. There are four guide wheels 14, which are set at the bottom of the dye box 13. They are used to guide the fabric to move along a specific path in the dye box 13. The movement path of the fabric in the dye box 13 can be flexibly planned according to actual production needs, increasing the contact time and contact area between the fabric and the dye, and further improving the dyeing effect. The bottom of the dye box 13 is rotatably connected with a tail wheel to guide the fabric between the rollers 12.

[0075] See Figures 3-6 As shown, the mixing turbulence assembly 2 is located inside the dye tank 13 and is used to mix the dyes inside the dye tank 13. The mixing turbulence assembly 2 includes a first active wheel 21, of which there are at least four, and which are rotatably connected to the rear end of the dye tank 13; a first passive wheel 22, which is rotatably connected to the middle of the rear end of the dye tank 13 and meshes with the first active wheel 21; an inner rotating rod 23, which is rotatably connected inside the dye tank 13 and is fixedly connected to the first passive wheel 22; a spiral plate 24, which consists of two sets and is symmetrically installed outside the inner rotating rod 23; liquid outlet holes 25, which are symmetrically opened inside the inner rotating rod 23 and correspond one-to-one with the spiral plates 24; a circulation pump 26, which is installed at the bottom front end of the dye tank 13, with its inlet end connected to the bottom of the dye tank 13 and its outlet end connected to the front end of the inner rotating rod 23; and a radial tension assembly, which is located inside the dye tank 13 and is used to stretch the fabric entering the dye tank 13.

[0076] When the continuous dyeing device for polyester fabric is started, the circulation pump 26 starts to operate, drawing the dye from the bottom of the dye box 13 and transporting it into the inner rotating rod 23. The dye flows out naturally through the symmetrically opened outlet holes 25 on the inner rotating rod 23 and enters the dye box 13.

[0077] Meanwhile, under the action of the feed roller 11 and tension roller 111, the fabric enters the guide wheel 14 at the bottom of the dye box 13 in an orderly manner. As the fabric moves around the guide wheel 14, the friction between the two causes the guide wheel 14 to rotate in the forward direction. Since the guide wheel 14 is connected to the first driving wheel 21, and there are at least four first driving wheels 21 rotatably connected to the rear end of the dye box 13, their rotation will drive the first driven wheel 22 meshing with it to rotate, thereby causing the inner rotating rod 23 to rotate in the reverse direction.

[0078] Two sets of spiral plates 24 are symmetrically installed on the outside of the inner rotating rod 23. When the inner rotating rod 23 rotates in the opposite direction, the spiral plates 24 stir the dye in the dye box 13. The dye flowing out and the original dye in the box are continuously circulated and mixed under the push of the spiral plates 24, and diffuse from the center of the dye box 13 to the surrounding area, so as to achieve full mixing of dye and provide a uniform dye environment for fabric dyeing. In addition, the tail wheel connected to the bottom of the dye box 13 is responsible for smoothly leading out the dyed fabric and entering the subsequent processing process.

[0079] By cooperating with the first active wheel 21 and the first passive wheel 22, the propulsion of the fabric is converted into the rotational power of the inner rotating rod 23. Combined with the stirring of the spiral plate 24 and the circulation of the dye, a multi-dimensional turbulence effect is formed. Compared with the traditional single stirring method, the dye mixing efficiency is greatly improved, and the dye reaches a highly uniform state in a short time. This effectively avoids the problem of color difference in fabric dyeing caused by uneven dyeing. At the same time, the friction generated by the fabric movement drives the mixing process, reducing the use of additional power devices and reducing the overall energy consumption of the equipment.

[0080] It is worth noting that, in order to adapt to different dye characteristics and fabric dyeing needs, the flow rate of the circulation pump 26 can also be adjusted by frequency conversion control to control the circulation speed and flow rate of the dye, and ensure that the dye mixing effect reaches the best state.

[0081] See Figures 7-9As shown, the mixing turbulence assembly 2 also includes: a rotating disk 221, which is rotatably connected to the outside of the front sealing cover 211; a second passive wheel 222, which is fixedly connected to the front end of the rotating disk 221; a third active wheel 223, which is rotatably connected to the dye box 13, and a motor for driving the third active wheel 223 to rotate is installed on the dye box 13; an axial stirring rod 224, which is annularly mounted on the rotating disk 221; and an auxiliary outer wheel 225, which is installed inside the axial stirring rod 224. An outer rotating rod 226 is rotatably connected between sealing covers 211 located at the front and rear ends, and a discharge hole is provided on the outer rotating rod 226; an auxiliary inner wheel 227 is installed at the front end of the outer rotating rod 226 and meshes with the auxiliary outer wheel 225; a liquid distribution pipe 228 is fixedly connected inside the sealing cover 211 located at the front end, the inlet end of the liquid distribution pipe 228 is connected to the outlet end of the circulating pump 26, and the outlet end of the liquid distribution pipe 228 is connected to the inner rotating rod 23 and the outer rotating rod 226 respectively.

[0082] The circulating pump 26 starts, drawing out the dye from the bottom of the dye tank 13. The outlet of the circulating pump 26 is connected to the distribution pipe 228, which transports the dye to the distribution pipe 228. The distribution pipe 228 divides the dye into two parts: one part enters the inner rotating rod 23, and the other part enters the outer rotating rod 226. The circulating pump 26 draws out the dye from the bottom of the dye tank 13 and transports it to the distribution pipe 228, which then distributes it to the inner rotating rod 23 and the outer rotating rod 226, thus realizing the recycling of the dye. This not only reduces dye waste and production costs but also reduces the discharge of dye waste liquid, which is beneficial to environmental protection. Afterward, the motor starts, driving the third driving wheel 223 to rotate in the reverse direction. Since the third driving wheel 223 meshes with the second driven wheel 222, the third driving wheel 223 drives the second driven wheel 222 to rotate in the forward direction. The second driven wheel 222 is fixedly connected to the rotating disk 221. At the front end, the rotating disk 221 also rotates in the same direction. Since the axial stirring rod 224 is installed in a ring on the rotating disk 221, the axial stirring rod 224 rotates in the same direction, stirring the dye liquor inside the dye box 13 in the same direction. When the axial stirring rod 224 rotates in the same direction, the auxiliary outer wheel 225 and the auxiliary inner wheel 227 mesh and drive the outer rotating rod 226 to rotate. The dye entering the outer rotating rod 226 flows out from the discharge hole opened on its outside to dye the fabric. Since the fabric has a circumferential structure under the guidance of the guide wheel 14, the discharge hole of the outer rotating rod 226 can spray the dye evenly on the outside of the fabric. At the same time, the stirring action of the axial stirring rod 224 further promotes the even distribution of dye around the fabric. Combined with the axial stirring rod 224's axial stirring of the dye liquor, the uniformity of the dye distribution around the fabric is further improved.

[0083] The dye is further stirred and mixed from multiple directions and angles by the axial stirring rod 224 and the counter-rotation and staggered arrangement of the inner rotating rod 23 and the spiral plate 24, so that the dye is fully mixed in the dye box 13, avoiding phenomena such as dye layering and precipitation, and ensuring the uniformity of dye concentration, which helps to improve the quality of fabric dyeing.

[0084] See Figures 4-5 As shown, the liquid outlet 25 is located at the front end of the spiral plate 24, so that when the inner rotating rod 23 rotates in the opposite direction, the dye flows along the shape of the spiral plate 24 when it is discharged from the liquid outlet 25.

[0085] Since the outlet hole 25 is located at the front end of the spiral plate 24 and the inner rotating rod 23 rotates in the opposite direction, after the dye is discharged from the outlet hole 25, it will be guided by the spiral plate 24. The spiral plate 24 has a spiral structure, and the dye will flow along the shape of the spiral plate 24, gradually flowing from the front end to the rear end. In this process, the dye continuously comes into contact with and collides with the surrounding dyes and other components in the dye liquor. Its flow path is greatly extended compared to straight flow, which allows the dye more time to fully mix with the surrounding dye liquor.

[0086] See Figures 4-5 As shown, each set of spiral plates 24 is arranged in an alternating pattern on the inner rotating rod 23, so that when the dye flows on the spiral plates 24, it collides with the adjacent dyes.

[0087] When the dyes flow on their respective spiral plates 24, due to the staggered arrangement, the dyes on different spiral plates 24 will meet. Since the dyes have a certain flow velocity and kinetic energy, they will collide with each other when they meet. The collision between the dyes breaks up the originally relatively independent dye clusters, and the dyes in different regions can come into contact and blend more fully. During the collision process, the mutual diffusion and exchange between dye molecules are intensified, thereby accelerating the dye mixing process and making the concentration and composition of the dye more uniform in the entire dye solution.

[0088] See Figures 4-5 As shown, a diffusion hole 241 is provided at the edge of the spiral plate 24 away from the inner rotating rod 23.

[0089] When the dye flows out of the outlet hole 25 and along the spiral plate 24, some of the dye diffuses outward through the diffusion hole 241. The diffusion hole 241 causes more turbulence and disturbance in the dye during the flow process. The dye flowing out of the diffusion hole 241 interacts with the surrounding dye to form a complex flow pattern, which further enhances the mixing effect of the dye, makes the dye composition more uniform, avoids the situation of excessively high or low local concentration, and thus improves the dyeing quality.

[0090] See Figures 7-10 As shown, the radial tension assembly includes: a sealing cover 211, of which two are symmetrically installed at the front and rear ends of the dye box 13, and are rotatably connected to the inner rotating rod 23 and the guide wheel 14; a radial box 212, which is installed inside the sealing cover 211, and a radial groove is formed between the radial box 212 and the sealing cover 211; a return spring 213, which is installed inside the radial box 212; a slide rail seat 214, which is connected to the radial groove of the radial box 212 through a slide rail fit; a radial roller 215, which is rotatably connected between the slide rail seats 214 at the front and rear ends; a radial rod 216, one end of which is fixedly connected inside the slide rail seat 214, and the other end of which slides through the outside of the radial box 212; and a cam 217, of which two are arranged in a group, and are rotatably connected inside the sealing cover 211 and fixedly connected to the inner rotating rod 23, and the cam 217 at the front end is rotatably connected to the dispensing pipe 228.

[0091] When using the mixing turbulence component 2, the rotation of the inner rotating rod 23 drives the rotation of the cam 217. Its irregular shape periodically squeezes the radial roller 215. When the protruding part of the cam 217 contacts the radial roller 215, it applies an outward force to the radial roller 215. After being squeezed by the cam 217, the radial roller 215 pushes the slide rail seat 214, which is rotatably connected to it. Therefore, under the push of the radial roller 215, the slide rail seat 214 will move centrifugally away from the sealing cover 211 along the radial groove. During the movement of the slide rail seat 214, the radial roller 215, connected between the front and rear slide rail seats 214, will also move accordingly, moving along the moving groove. At this time, a tension is applied to the fabric, thereby stretching or shrinking the fabric. When the protruding part of the cam 217 leaves the radial roller 215, the previously compressed return spring 213 will restore its elastic deformation, pushing the slide rail seat 214 to move closer to the sealing cover 211, so that the radial roller 215 returns to its initial position, preparing for the next stretching or shrinking. During the dyeing process, tension is applied to the fabric. By periodically stretching the fabric, the fabric is fully unfolded in the dye box 13, increasing the contact area between the fabric and the dye. This helps the dye to penetrate the fabric more evenly, avoiding uneven dyeing caused by fabric wrinkles or stacking, thereby improving the dyeing quality.

[0092] It is worth noting that the tension roller 111 is located below the feed roller 11. The tension roller 111 mainly adjusts the tension of the fabric by its own rotation and friction with the fabric, so that the fabric is kept in a certain tight state when it enters the dyeing device, ensuring that the fabric is transported smoothly. The radial tension component is located inside the dye box 13, thereby stretching the fabric. It is a dynamic and periodic tension application method, which further optimizes the state of the fabric and focuses more on improving the dyeing effect of the fabric during the dyeing process. By stretching the fabric, the penetration and uniformity of the dye are increased.

[0093] See Figure 3 and Figure 11 As shown, the dye collection assembly 3 is located at the bottom of the dye tank 13 and is used to collect excess dye. The dye collection assembly 3 includes: a collection tank 31, which is installed at the arc-shaped bottom of the dye tank 13 and is connected to the dye tank 13; the top of the collection tank 31 has a linearly arranged conical groove 311; the bottom of each set of conical grooves 311 has a feed groove 312; and the bottom of the collection tank 31 has a drain groove 313 connected to the circulating pump 26. The drain groove 313 and the feed groove 312 are connected.

[0094] The bottom of the dye box 13 has an arc-shaped structure. When the dye in the dye box 13 settles to the bottom due to natural settling, fabric compression, etc., the dye will converge to the lowest point of the bottom of the dye box 13 based on gravity and the guiding effect of the arc-shaped bottom. The settled dye will naturally flow into the collection box 31. By setting a conical groove 311, the dye flowing into the collection box 31 is guided by its special conical structure. The dye flows down the inner wall of the conical groove 311 to the bottom and finally enters the internal channel of the collection box 31 through the feed groove 312 opened at the bottom of the conical groove 311. Through the cooperation of the arc-shaped bottom of the dye box 13 and the conical groove 311 of the collection box 31, the settled and excess dye can be collected quickly and efficiently.

[0095] The tip plate 32 is installed inside the feed trough 312. The tip of the tip plate 32 is located at the bottom of the conical groove 311. The tip design of the tip plate 32 reduces the obstruction of dye flow. At the same time, when the circulation pump 26 is working, the suction and pressure generated by the circulation pump 26 cause the dye to pass quickly from the tip of the tip plate 32, flow along the feed trough 312 to the drain trough 313, and finally be drawn out by the circulation pump 26 through the drain trough 313 and transported back to the dye tank 13 for recycling. This ensures the stable operation of the dye collection component 3 and the entire pad dyeing device, reduces downtime maintenance time caused by blockage, and realizes the recycling of dye. The sediment and excess dye that might otherwise be wasted are sent back to the dye tank 13 to participate in the dyeing process, reducing dye consumption and thus reducing the dye procurement cost in the pad dyeing process of polyester fabric.

[0096] See Figure 3 As shown, a spiral limiting plate 33 is installed inside the arc-shaped dye box 13.

[0097] The bottom of the dye tank 13 is arc-shaped, making it easy for the dye to accumulate at the bottom. The spiral structure of the spiral limiting plate 33 provides a specific flow path for the dye at the bottom. On the one hand, when the axial stirring rod 224 rotates and drives the dye liquor to flow, the dye at the bottom will be guided upward or diffused in all directions along the spiral trajectory of the spiral limiting plate 33, avoiding local accumulation of dye at the bottom and allowing the originally deposited dye to participate in the overall mixing process again. On the other hand, when the dye at the bottom rises or diffuses along the spiral trajectory, it will collide strongly with the surrounding flowing dye liquor and other dyes at the bottom, so that the dye particles are fully dispersed, thereby achieving the homogenization of the dye at the bottom.

[0098] The spiral limiting plate 33 may guide the dye to flow along a specific spiral path, making the flow path of the dye in the dye box 13 more regular and prolonging the flow time of the dye in the box.

[0099] A continuous pad-dyeing process for polyester fabrics, the specific steps of which are as follows:

[0100] First, the circulation pump 26 starts working, extracting the dye from the bottom of the dye tank 13 and dividing the dye into two parts through the separator 228. These parts are then transported to the inner rotating rod 23 and the outer rotating rod 226 respectively, providing a raw material circulation basis for subsequent dye mixing and dyeing, realizing the reuse of dye and reducing waste.

[0101] Second, the fabric is kept taut under the action of the feed roller 11 and the tension roller 111, and enters the four guide wheels 14 at the bottom of the dye box 13 in an orderly manner. When the fabric moves around the guide wheels 14, the friction between them causes the guide wheels 14 to rotate in the same direction, and at the same time drives the first active wheel 21 connected to it to rotate, providing power input for the mixing turbulence component 2.

[0102] Third, the rotation of the first driving wheel 21 drives the rotation of the first driven wheel 22 meshing with it. The first driven wheel 22 is fixedly connected to the inner rotating rod 23, thereby causing the inner rotating rod 23 to rotate in the opposite direction. The spiral plate 24 outside the inner rotating rod 23 stirs the dye. The dye flowing out of the outlet hole 25 and the original dye in the tank are circulated and mixed under the push of the spiral plate 24, and diffuse from the center of the dye tank 13 to the surrounding area.

[0103] Fourth, the motor starts and drives the third active wheel 223 to rotate in the reverse direction. Through meshing with the second passive wheel 222, it drives the rotating disk 221 to rotate in the forward direction, so that the axial stirring rod 224, which is mounted on the rotating disk 221, stirs the dye in the forward direction. At the same time, the axial stirring rod 224 drives the outer rotating rod 226 to rotate through the meshing transmission of the auxiliary outer wheel 225 and the auxiliary inner wheel 227. The discharge hole of the outer rotating rod 226 sprays the dye evenly on the outside of the fabric.

[0104] Fifth, the rotation of the inner rotating rod 23 drives the cam 217, which is fixedly connected to it, to rotate. The irregular shape of the cam 217 periodically squeezes the radial roller 215. When the protruding part of the cam 217 contacts the radial roller 215, it pushes the slide rail seat 214 to make centrifugal motion along the radial groove, so that the radial roller 215 applies a pulling force to the fabric to achieve stretching.

[0105] Sixth, the dye that settles to the bottom gathers at the lowest point under the action of gravity and flows into the collection box 31. The conical groove 311 at the top of the collection box 31 guides the dye into the feed trough 312. The tip plate 32 reduces the flow resistance of the dye. Under the suction and pressure of the circulating pump 26, the dye is extracted through the drain trough 313 and sent back to the dye box 13 for recycling.

[0106] Seventh, the spiral limiting plate 33 inside the arc of the dye box 13 provides a specific spiral flow path for the dye that settles to the bottom. When the axial stirring rod 224 rotates and drives the dye liquor to flow, the dye that settles to the bottom diffuses along the trajectory of the spiral limiting plate 33 and collides and disperses with the surrounding dye liquor to avoid accumulation at the bottom.

[0107] The continuous dyeing apparatus and dyeing process for polyester fabric described in this application organically combine the fabric's propulsion power with the dye circulation system. The frictional force generated by the fabric's movement is converted into the driving force of the inner rotating rod using guide wheels and gear sets. Combined with the counter-current stirring of the spiral plate and the forward stirring of the axial stirring rod, multi-dimensional turbulence is formed within the dye tank, significantly improving the uniform mixing efficiency of the dye in a short time. Simultaneously, a dynamic radial tension component is used to periodically stretch the fabric, ensuring it remains flat and fully expanded throughout the dyeing process. This increases the contact area between the dye and the fabric and avoids color differences caused by wrinkles and stacking. The combined design of the feed roller and tension roller ensures stable tension during the fabric introduction stage. The arc-shaped bottom structure, along with the dye collection component and tip plate design, efficiently recovers settled and excess dye, which can be reused via a circulation pump. This reduces dye waste and wastewater discharge, lowering production costs. The spiral limiting plate further guides the settled dye to diffuse along a specific path and collide with the flowing dye liquor for remixing, effectively preventing dye deposition and stratification. Thus, while ensuring dyeing quality and uniformity, energy consumption and environmental protection requirements are also considered.

[0108] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A continuous dyeing apparatus for polyester fabric, characterized in that... ,include: Dyeing rack (1); A feed roller (11) is provided on one side of the top of the dyeing rack (1), and a tension roller (111) is provided below the feed roller (11). Roller (12) is symmetrically arranged on the other side of the dyeing rack (1); The dye box (13) is located below the dyeing rack (1) and has an arc-shaped bottom. Guide wheels (14) are provided in multiple quantities and are located at the bottom of the dye box (13) to guide the fabric to travel along a specific path in the dye box (13). The bottom of the dye box (13) is rotatably connected with tail wheels. A mixing turbulence component (2) is disposed inside the dye box (13) for mixing the dyes in the dye box (13); The hybrid turbulence component (2) includes: The first drive wheel (21) has at least four of them and is rotatably connected to the rear end of the dye box (13); The first passive wheel (22) is rotatably connected to the middle of the rear end of the dye box (13) and meshes with the first active wheel (21); The inner rotating rod (23) is rotatably connected inside the dye box (13) and fixedly connected to the first passive wheel (22); Spiral plates (24) are arranged in two groups and are symmetrically installed outside the inner rotating rod (23); The liquid outlet (25) is symmetrically opened inside the inner rotating rod (23) and corresponds one-to-one with the spiral plate (24); The circulating pump (26) is installed at the bottom front end of the dye box (13), with its inlet end connected to the bottom of the dye box (13) and its outlet end connected to the front end of the inner rotating rod (23). The hybrid turbulence component (2) also includes: A rotating disk (221) is rotatably connected to the outside of the front sealing cover (211); The second passive wheel (222) is fixedly connected to the front end of the rotating disk (221); The third drive wheel (223) is rotatably connected to the end of the dye box (13); An axial stirring rod (224) is mounted in a ring on a rotating disk (221); An auxiliary outer wheel (225) is installed inside the axial stirring rod (224); The outer rotating rod (226) is rotatably connected between the sealing covers (211) located at the front and rear ends; An auxiliary inner wheel (227) is mounted on the front end of the outer rotating rod (226) and meshes with the auxiliary outer wheel (225); A liquid separator (228) is fixedly connected inside the sealing cover (211) at the front end. The inlet end of the liquid separator (228) is connected to the outlet end of the circulating pump (26). The outlet end of the liquid separator (228) is connected to the inner rotating rod (23) and the outer rotating rod (226) respectively. A radial tension assembly, disposed inside the dye box (13), is used to stretch the fabric entering the dye box (13); the radial tension assembly includes: Two sealing covers (211) are provided and are symmetrically installed at the front and rear ends of the dye box (13). They are rotatably connected to the inner rotating rod (23) and the guide wheel (14). A radial box (212) is installed inside a sealing cover (211), and a radial groove is provided between the radial box (212) and the sealing cover (211); A return spring (213) is installed inside the radial box (212); The slide rail seat (214) is connected to the radial groove of the radial box (212) by a slide rail fit; A radial roller (215) is rotatably connected between slide rail seats (214) at both the front and rear ends; A radial rod (216) has one end fixedly connected inside the slide rail seat (214) and the other end sliding through the outside of the radial box (212); Cams (217) are in pairs and are rotatably connected inside the sealing cover (211) and fixedly connected to the inner rotating rod (23); A dye collection assembly (3) is located at the bottom of the dye box (13) for collecting excess dye; A spiral limiting plate (33) is installed inside the arc of the dye box (13).

2. The continuous dyeing apparatus for polyester fabric according to claim 1, characterized in that, The outlet hole (25) is located at the front end of the spiral plate (24) so ​​that when the inner rotating rod (23) rotates in the opposite direction, the dye flows along the shape of the spiral plate (24) when it is discharged from the outlet hole (25).

3. The continuous dyeing apparatus for polyester fabric according to claim 2, characterized in that, Each set of spiral plates (24) is staggered on the inner rotating rod (23) so that when the dye flows on the spiral plate (24), the dye adjacent to it collides with each other.

4. The continuous dyeing apparatus for polyester fabric according to claim 3, characterized in that, The spiral plate (24) has a diffusion hole (241) at the edge away from the inner rotating rod (23).

5. The continuous dyeing apparatus for polyester fabric according to claim 1, characterized in that, The dye collection assembly (3) includes: A collection box (31) is installed at the arc-shaped bottom of the dye box (13) and is connected to the dye box (13). The top of the collection box (31) is provided with linearly arranged conical grooves (311). The bottom of each set of conical grooves (311) is provided with a feed groove (312). The bottom of the collection box (31) is provided with a drain groove (313) connected to the circulating pump (26). The drain groove (313) and the feed groove (312) are connected. A tip plate (32) is installed inside the feed trough (312), with the tip of the tip plate (32) positioned at the bottom of the conical groove (311).

6. A continuous dyeing process for polyester fabrics, employing the continuous dyeing apparatus for polyester fabrics as described in any one of claims 1-5, characterized in that: The specific steps are as follows: S1: The circulation pump (26) is started, and the dye at the bottom of the dye box (13) is extracted and distributed to the two circulation channels of the inner rotating rod (23) and the outer rotating rod (226) through the separator (228); S2: After the fabric is tensioned by the feed roller (11) and tension roller (111), it moves around the guide wheel (14) and drives the first drive wheel (21) to provide energy for the mixing turbulence component (2); S3: The first active wheel (21) is linked with the first passive wheel (22) to make the inner rotating rod (23) rotate in the opposite direction, and the spiral plate (24) stirs the dye and forms multidimensional turbulence from the center to the periphery; S4: The motor drives the third drive wheel (223), which in turn drives the axial stirring rod (224) to stir in the same direction, and the outer rotating rod (226) sprays the dye evenly onto the fabric. S5: The inner rotating rod (23) drives the cam (217) to periodically squeeze the radial roller (215), pushing the slide rail seat (214) to stretch the fabric by the radial roller (215); S6: The dye collected in the bottom collection box (31) is pumped back to the dye box (13) for circulation through the conical groove (311) and the feed trough (312) under the action of the circulation pump (26); S7: The spiral limiting plate (33) inside the arc of the dye box (13) plans the spiral flow path for the dye that sinks to the bottom. When the axial stirring rod (224) drives the dye liquor to flow, it guides the dye that sinks to the bottom to diffuse, so that it collides and disperses with the surrounding dye liquor.

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