Dyeing system and method of use

Abstract

The invention relates to the technical field of dyeing, in particular to a dyeing system and a using method, and the dyeing system comprises a dyeing kettle, a dye box and a material supporting piece. The dye box is arranged in the dyeing kettle and comprises a box body, a dye supporting pipe and a dye layer, an inflow port of the dye supporting pipe is communicated with an input port of the dyeing kettle, the dye supporting pipe is partially inserted into the box body and provided with a ventilation section, and a first blocking end of the dye supporting pipe and the ventilation section are both located in the box body. A plurality of ventilation holes are uniformly formed in the side wall of the ventilation section, the dye layer is wound on the ventilation section, the dye layer comprises a porous loading layer and dye uniformly arranged on the porous loading layer, the box body comprises an outflow opening, and the outflow opening is communicated with a gathering space between the box body and the ventilation section. The material supporting piece is arranged in the dyeing kettle and used for supporting materials. The dyeing medium sequentially flows through the input port, the inflow port, the vent hole, the dye layer, the gathering space, the outflow port, the material and the output port.

Description

Technical Field

[0001] This invention relates to the field of dyeing technology, and in particular to a dyeing system and its method of use. Background Technology

[0002] Supercritical carbon dioxide anhydrous dyeing technology uses carbon dioxide instead of water as the dyeing medium, fundamentally solving the problems of high water consumption and difficult water pollution treatment, and enabling a green production process with reduced emissions, reduced consumption, and zero pollution. However, in existing technologies, supercritical carbon dioxide anhydrous dyeing systems typically include dozens of components, such as a carbon dioxide gas source, storage tank, multiple heat exchangers (heaters / coolers), high-pressure pump, dyeing vessel, dyeing vessel, separator, multiple valves, and lengthy connecting pipelines. Existing supercritical carbon dioxide anhydrous dyeing systems have the following drawbacks:

[0003] 1. The equipment is highly complex, and both its manufacturing and maintenance costs are relatively high.

[0004] 2. The pipes between the dyeing kettle and the dyeing kettle are long and have many joints. A lot of dye is adsorbed and remains in the pipes and joints. Changing the color of the dye requires a long cleaning time, which affects the dyeing efficiency.

[0005] 3. The flow rate and velocity of supercritical carbon dioxide vary greatly in different parts of the dyeing kettle, resulting in uneven dye dissolution and unstable dye concentration in the fluid fed into the dyeing kettle. This can easily lead to color differences within and between batches, resulting in a low first-pass dyeing rate. Summary of the Invention

[0006] One object of the present invention is to provide a dyeing system that can reduce manufacturing and maintenance costs, improve dyeing efficiency, and increase the first-pass dyeing qualification rate.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A staining system is provided, comprising:

[0009] A dyeing vessel, the dyeing vessel having an inlet and an outlet;

[0010] A dye box is disposed inside the dyeing kettle. The dye box includes a box body, a dye support tube, and a dye layer. The dye support tube has an inlet and a first sealing end at its two ends along its own axis. The inlet is connected to the input port. The dye support tube is partially inserted into the box body and has a venting section. The first sealing end and the venting section are both located inside the box body. Multiple venting holes are evenly opened on the side wall of the venting section. The dye layer is wound around the venting section and includes a porous load layer and dye evenly disposed on the porous load layer. The box body includes an outlet that is connected to the collection space between the box body and the venting section.

[0011] A material support component is disposed inside the dyeing kettle and is used to support the material.

[0012] The dyeing system is configured such that a dyeing medium can flow sequentially through the inlet, the outlet, the vent, the dye layer, the collection space, the outlet, the material, and the output port, so that the dyeing medium can dissolve and carry the dye to dye the material.

[0013] Optionally, the porous support layer is a molecular membrane, on which a plurality of flow pores are uniformly formed, and the pore size of the flow pores is larger than the particle size of the dissolved disperse dye.

[0014] And / or, the undissolved dye has a particulate structure, and the pore size of the flow hole is smaller than the minimum size of the particulate structure.

[0015] Optionally, the ventilation section is wound with multiple layers of the porous load layer from the inside to the outside, and the dye is uniformly spread between any two adjacent layers of the porous load layer;

[0016] And / or, the cross-section of the dye support tube is circular or a regular polygon;

[0017] And / or, the outlet is coaxially arranged with the dye support tube;

[0018] And / or, the housing is coaxially arranged with the dye support tube;

[0019] And / or, the dye support tube is capable of rotating about its own axis.

[0020] Optionally, the material support is a tubular structure, with an inlet and a sealing end at its two ends along its axial direction, the inlet being connected to the outlet, the material support having a support section, and a plurality of flow holes uniformly formed on the sidewall of the support section, the material being wound around the support section.

[0021] Optionally, the tubular structure is coaxially arranged with the box body;

[0022] And / or, the tubular structure is detachably connected to the box body;

[0023] And / or, the box body is detachably connected to the dyeing vessel;

[0024] And / or, the tubular structure is detachably connected to the dyeing vessel;

[0025] And / or, the tubular structure is capable of rotating about its own axis.

[0026] Optionally, the dyeing system includes M dyeing units, where M is a positive integer greater than 1, and each dyeing unit includes the dyeing kettle, the dye box and the material support disposed within the dyeing kettle.

[0027] Optionally, the system also includes a storage tank, wherein the input port of the dyeing vessel of each dyeing unit is connected to the output port of the storage tank, and the output port of the dyeing vessel of each dyeing unit is connected to the input port of the storage tank.

[0028] Optionally, each of the staining units includes a pressure boosting valve located on the pipeline between the output end and the input port;

[0029] And / or, each of the staining units includes a pressure relief valve located on the pipeline between the output port and the input port.

[0030] Optionally, each staining unit further includes a circulation pipeline, one end of which is connected to the pipeline between the pressure boosting valve and the inlet, and the other end of which is connected to the pipeline between the outlet and the pressure relief valve. Each circulation pipeline is equipped with a circulation pump.

[0031] Each of the aforementioned circulation lines is also equipped with a filter, a flow meter, and / or an exhaust valve.

[0032] Another objective of this invention is to provide a method of use that can reduce manufacturing and maintenance costs, improve dyeing efficiency, and increase the first-pass dyeing yield.

[0033] To achieve this objective, the present invention adopts the following technical solution:

[0034] A method of use is provided for the above-mentioned staining system, the method comprising the following steps:

[0035] Preparation stage: Calculate the dye loading according to the dyeing requirements of the material, wind the corresponding dye layer onto the dye support tube according to the dye loading, assemble the dye support tube with the box, assemble the dye box with the material support to obtain the dyeing module, and assemble the dyeing module into the dyeing kettle.

[0036] Injection phase: Carbon dioxide is injected into each staining unit until the carbon dioxide is in a supercritical state;

[0037] Dyeing stage: Supercritical carbon dioxide passes through the dyeing kettle and circulates. The circulation time is controlled according to the cumulative circulation flow rate of supercritical carbon dioxide and the dyeing depth requirements of the material.

[0038] Recovery phase: Depressurization and recovery of supercritical carbon dioxide.

[0039] The beneficial effects of this invention are:

[0040] This invention provides a dyeing system, including a dyeing kettle, a dye box, and a material support. The dyeing kettle has an inlet and an outlet. The dye box is disposed within the dyeing kettle and includes a box body, a dye support tube, and a dye layer. The dye support tube has an inlet and a first sealing end at its two ends along its axial direction, respectively. The inlet is connected to the inlet. The dye support tube is partially inserted into the box body and has a venting section. Both the first sealing end and the venting section are located within the box body. Multiple vent holes are evenly distributed on the side wall of the venting section. The dye layer is wound around the venting section and includes a porous load layer and dye evenly distributed on the porous load layer. The box body includes an outlet, which is connected to a collection space between the box body and the venting section. The material support is disposed within the dyeing kettle and is used to support the material. The dyeing system is configured such that the dyeing medium can sequentially flow through the inlet, inlet, vent holes, dye layer, collection space, outlet, material, and outlet, so that the dyeing medium can dissolve and carry the dye to dye the material. By placing both the dye box and the material to be dyed within the dyeing kettle, the length of the connecting pipes can be significantly reduced, thereby greatly minimizing the adsorption of residual dye in the pipes. This eliminates the need for lengthy cleaning when changing dye colors, thus improving dyeing efficiency. Furthermore, the complexity of the device is greatly reduced, lowering both equipment and maintenance costs. In addition, compared to existing technologies that place dye at different heights within the dyeing kettle, the flow rate and velocity of supercritical carbon dioxide at each vent of the dye support tube in this dye box are more similar. The paths of supercritical carbon dioxide through the dye layer at each vent are also more similar, resulting in a more consistent concentration of disperse dye in the fluid flowing out of the dye layer along its circumference. This leads to a more stable concentration of disperse dye in the fluid flowing to the outlet, helping to avoid color difference problems caused by unstable disperse dye concentration and thus improving the first-pass dyeing yield.

[0041] This invention also provides a method of use for the aforementioned dyeing system. The method includes the following steps: Preparation stage: Calculate the dye load according to the dyeing requirements of the material; wind the corresponding dye layer onto the dye support tube according to the dye load; assemble the dye support tube and the box; assemble the dye box and the material support to obtain the dyeing module; assemble the dyeing module into the dyeing kettle; Injection stage: Inject carbon dioxide into each dyeing unit until the carbon dioxide reaches a supercritical state; Dyeing stage: Supercritical carbon dioxide passes through the dyeing kettle and circulates; control the circulation time according to the cumulative circulation flow rate of supercritical carbon dioxide and the dyeing depth requirements of the material; Recovery stage: Depressurize and recover the supercritical carbon dioxide. Applying this method to the dyeing system can reduce manufacturing and maintenance costs, improve dyeing efficiency, and increase the first-pass dyeing qualification rate. Attached Figure Description

[0042] Figure 1 This is a partial structural cross-sectional view of a staining unit provided in an embodiment of the present invention;

[0043] Figure 2 This is a cross-sectional view of the dye box provided in an embodiment of the present invention;

[0044] Figure 3 This is a schematic diagram of the staining system provided in an embodiment of the present invention;

[0045] Figure 4 This is a flowchart illustrating the usage method provided in the embodiments of the present invention.

[0046] In the picture:

[0047] 1. Staining unit; 11. Staining vessel; 111. Inlet; 112. Outlet;

[0048] 12. Dye box; 121. Box body; 1211. Output pipe; 1212. Guide pipe; 122. Dye support pipe; 1221. Vent hole; 1222. Connecting pipe; 123. Dye layer; 124. First sealing ring; 125. Collection space;

[0049] 13. Material support component; 131. Support section; 1311. Flow hole; 132. Assembly pipe; 133. Second sealing ring;

[0050] 14. Pressure boosting valve; 15. Pressure relief valve; 16. Circulation pipeline; 17. Circulation pump; 18. Filter; 19. Flow meter; 110. Exhaust valve;

[0051] 2. Storage tank; 3. Booster pump; 4. Recovery pump;

[0052] 800. Materials. Detailed Implementation

[0053] Before explaining any implementation of this application in detail, it should be understood that this application is not limited to its application to the structural details and component arrangements set forth in the following description or shown in the above drawings.

[0054] In this application, the terms "comprising," "including," "having," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0055] In this application, the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this application generally indicates that the preceding and following related objects have an "and / or" relationship.

[0056] In this application, the terms "connection," "combination," "coupling," and "installation" can refer to direct connection, combination, coupling, or installation, or indirect connection, combination, coupling, or installation. For example, a direct connection refers to two parts or components being connected together without the need for an intermediary, while an indirect connection refers to two parts or components each being connected to at least one intermediary, with the connection achieved through the intermediary. Furthermore, "connection" and "coupling" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.

[0057] In this application, those skilled in the art will understand that relative terms (e.g., “about,” “approximately,” “basically,” etc.) used in conjunction with quantities or conditions are to include the values ​​and have the meaning indicated by the context. For example, such relative terms include at least the degree of error associated with the measurement of a particular value, tolerances associated with the particular value due to manufacturing, assembly, use, etc. Such terms should also be considered as disclosing a range defined by the absolute values ​​of the two endpoints. Relative terms may refer to a certain percentage (e.g., 1%, 5%, 10% or more) of the indicated value. Numerical values ​​that do not use relative terms should also be disclosed as specific values ​​with tolerances. Furthermore, “basically” when expressing relative angular relationships (e.g., substantially parallel, substantially perpendicular) may refer to a certain degree (e.g., 1 degree, 5 degrees, 10 degrees or more) added to or subtracted from the indicated angle.

[0058] In this application, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.

[0059] In this application, the directional terms "upper," "lower," "left," "right," "front," and "rear" are used to describe the orientation and positional relationships shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should be understood that when an element is mentioned as being connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as upper side, lower side, left side, right side, front side, and rear side not only represent positive orientation but can also be understood as lateral orientation. For example, "below" can include directly below, lower left, lower right, lower front, and lower rear.

[0060] Supercritical carbon dioxide anhydrous dyeing technology uses carbon dioxide instead of water as the dyeing medium, fundamentally solving the problems of high water consumption and difficult water pollution treatment, and enabling a green production process with reduced emissions, reduced consumption, and zero pollution. However, in existing technologies, supercritical carbon dioxide anhydrous dyeing systems typically include dozens of components, such as a carbon dioxide gas source, storage tank, multiple heat exchangers (heaters / coolers), high-pressure pump, dyeing vessel, dyeing vessel, separator, multiple valves, and lengthy connecting pipelines. Existing supercritical carbon dioxide anhydrous dyeing systems have the following drawbacks:

[0061] 1. The equipment is highly complex, and both its manufacturing and maintenance costs are relatively high.

[0062] 2. The pipes between the dyeing kettle and the dyeing kettle are long and have many joints. A lot of dye is adsorbed and remains in the pipes and joints. Changing the color of the dye requires a long cleaning time, which affects the dyeing efficiency.

[0063] 3. The flow rate and velocity of supercritical carbon dioxide vary greatly in different parts of the dyeing kettle, resulting in uneven dye dissolution and unstable dye concentration in the fluid fed into the dyeing kettle. This can easily lead to color differences within and between batches, resulting in a low first-pass dyeing rate.

[0064] Therefore, this embodiment provides a dyeing system to solve the above problems. This dyeing system can reduce manufacturing and maintenance costs, improve dyeing efficiency, and increase the first-pass dyeing qualification rate.

[0065] like Figures 1-3As shown, the dyeing system of this embodiment includes a dyeing kettle 11, a dye box 12, and a material support 13. The dyeing kettle 11 has an inlet 111 and an outlet 112. The dye box 12 is disposed inside the dyeing kettle 11 and includes a box body 121, a dye support tube 122, and a dye layer 123. The dye support tube 122 has an inlet and a first sealing end at its two ends along its axial direction, respectively. The inlet is connected to the inlet 111. The dye support tube 122 is partially inserted into the box body 121 and has a venting section. Both the first sealing end and the venting section are located within the box body 121. Multiple vent holes 1221 are evenly distributed on the side wall of the venting section. The dye layer 123 is wound around the venting section and includes a porous load layer and dye evenly distributed on the porous load layer. The box body 121 includes an outlet, which is connected to the collection space 125 between the box body 121 and the venting section. Material support 13 is disposed inside dyeing kettle 11, and is used to support material 800. The dyeing system is configured such that the dyeing medium flows sequentially through inlet 111, inlet, vent 1221, dye layer 123, collection space 125, outlet, material 800, and outlet 112, so that the dyeing medium can dissolve and carry dye to dye material 800. By placing both dye box 12 and material 800 to be dyed in dyeing kettle 11, the length of connecting pipes can be greatly reduced, thus greatly reducing the amount of dye adsorbed in the pipes. When changing the color of dye, long-term cleaning is no longer required, thereby improving dyeing efficiency. Furthermore, the complexity of the device is greatly reduced, and equipment and maintenance costs are lowered. In addition, compared with the prior art where dyes are placed at different heights in the dye tank, the flow rate and flow rate of supercritical carbon dioxide at each vent 1221 of the dye support tube 122 of the dye box 12 are more similar, and the path of supercritical carbon dioxide through the dye layer 123 at each vent 1221 is more similar. That is, the concentration of disperse dye in the fluid flowing out of the dye layer 123 along the circumference of the dye layer 123 will be more similar. Therefore, the concentration of disperse dye in the fluid flowing to the outlet will be more stable, which can help avoid color difference problems caused by unstable concentration of disperse dye in the fluid, thereby improving the first dyeing pass rate.

[0066] Optionally, the porous support layer is a molecular membrane, on which multiple flow pores are uniformly formed. The pore size of the flow pores is larger than the particle size of the dissolved disperse dye, meaning that supercritical carbon dioxide can carry the dissolved disperse dye smoothly through the flow pores.

[0067] Compared to other porous materials, the molecular membrane has a thinner thickness, which helps to shorten the flow path of supercritical carbon dioxide, improve dye dissolution efficiency, and thus improve dyeing efficiency. Furthermore, the molecular membrane has a uniform thickness, avoiding localized issues of excessively high or low thickness. The extension length of the flow holes is also consistent throughout, eliminating problems such as inconsistent flow hole extension directions and path lengths found in porous materials manufactured using processes like metal sintering. In addition, compared to metal-sintered porous materials, the molecular membrane has a more uniform distribution of multiple flow holes, and the pore size is easier to control, resulting in higher pore size precision. This further improves the uniformity of disperse dye concentration in the fluid flowing out of dye layer 123 along its circumference, thereby further improving the stability of disperse dye concentration in the fluid flowing to the outlet, preventing color differences, and further increasing the first-pass dyeing yield.

[0068] Optionally, undissolved dye has a particulate structure. The pore size of the flow-through pores is smaller than the minimum size of the particulate structure to prevent undissolved dye from flowing with supercritical carbon dioxide. Only dissolved disperse dye can diffuse to and adsorb onto the fiber surface, then penetrate the fiber interior for diffusion and fixation, achieving dyeing. Therefore, undissolved dye flowing with supercritical carbon dioxide to the material 800°C becomes ineffective, causing unstable dyeing quality and dye waste. Setting the pore size of the molecular membrane's flow-through pores to be smaller than the minimum size of the particulate structure prevents undissolved dye from flowing with supercritical carbon dioxide, avoiding dye waste. With no dye waste, the amount of dye input for a single dyeing cycle can be precisely controlled, transforming from extensive feeding to quantitative supply. Furthermore, almost all dye is used for dyeing, with no residual dye adhering to the walls of other components. No additional cleaning is required during color changes, improving dyeing efficiency.

[0069] By precisely controlling the aperture of the flow holes, the amount of dye applied in a single batch can be locked within the target range during the production of dye box 12, achieving precise control of the front end of the dyeing process. Furthermore, by precisely controlling the amount of dye, excess undyed dye can be prevented from being present in the recovered carbon dioxide. The recovered carbon dioxide is pure, eliminating the need for multi-stage cooling and filtration in the recovery pipeline, thus significantly reducing the number of devices and lowering system and maintenance costs.

[0070] Optionally, in this embodiment, the particle size of the undissolved dye is less than 100 micrometers to increase the contact area with supercritical carbon dioxide and improve the dissolution efficiency. Preferably, the particle size of the undissolved dye is further less than 50 micrometers. More preferably, the particle size of the undissolved dye is further less than 30 micrometers.

[0071] Optionally, the ventilation section is wound with multiple porous load layers from the inside to the outside, and dye is uniformly laid between any two adjacent porous load layers. That is, the position of the dye can be fixed by sandwiching the dye between two adjacent molecular membranes, so as to ensure that the dye is always uniformly distributed.

[0072] Optionally, in this embodiment, the cross-section of the dye support tube 122 is circular. In other embodiments, the cross-section of the dye support tube 122 may also be a regular polygon, such as an equilateral triangle, square, regular pentagon, regular hexagon, or other regular polygon.

[0073] Optionally, the outlet is coaxially arranged with the dye support tube 122, that is, at the same axial position of the dye support tube 122, the path length of the fluid reaching the outlet along the circumference is consistent, which helps to ensure the stability of the concentration of disperse dye in the fluid flowing to the outlet.

[0074] Optionally, the box 121 and the dye support tube 122 are coaxially arranged, that is, the combined space 125 between the dye box 12 and the dye support tube 122 is an annular space. The width of the annular space is consistent in all directions along the circumference, which can further ensure the stability of the concentration of disperse dye in the fluid flowing to the outlet.

[0075] Optionally, in this embodiment, the cross-section of the box 121 is circular. In other embodiments, the cross-section of the box 121 may also be a regular polygon, such as an equilateral triangle, a square, a regular pentagon, a regular hexagon, or other regular polygons.

[0076] Optionally, the box body 121 has an outwardly protruding guide tube 1212 at one end along its own axial direction and an outwardly protruding output tube 1211 at the other end. Both the guide tube 1212 and the output tube 1211 protrude along the axial direction of the box body 121. Optionally, the dye support tube 122 has an outwardly protruding connecting tube 1222 at the end with the inlet. The connecting tube 1222 is connected to the ventilation section and is coaxially inserted into the guide tube 1212. Through the insertion and assembly of the two, the box body 121 and the dye support tube 122 can be coaxially arranged. Optionally, the end of the connecting tube 1222 away from the ventilation section abuts against the inner wall of the dyeing kettle 11, and the inlet 111 communicates with the connecting tube 1222.

[0077] Optionally, the dye box 12 further includes a first sealing ring 124, which is coaxially sleeved on the connecting pipe 1222 and sandwiched between the connecting pipe 1222 and the guide pipe 1212. Optionally, the inner wall of the guide pipe 1212 has a first limiting groove, and the first sealing ring 124 is located in the first limiting groove to prevent the first sealing ring 124 from moving.

[0078] Optionally, in some embodiments, the dye support tube 122 can rotate around its own axial direction to further improve the uniformity of the dissolved dye concentration in the fluid along the circumference of the dye support tube 122. Optionally, the housing 121 rotates synchronously with the dye support tube 122, or the housing 121 does not rotate, but the housing 121 and the dye support tube 122 are connected in a relative rotational and sealed manner, which can be achieved by setting a structure such as a sealed bearing. Optionally, the driving component for driving the dye support tube 122 to rotate can be a motor, which can be set inside the dyeing kettle 11 or outside the dyeing kettle 11, and then the output end of the motor and the dye support tube 122 are connected through a transmission structure such as a transmission shaft.

[0079] Optionally, the material support 13 is a tubular structure, with an inlet and a second sealing end at its two ends along its axial direction. The inlet is connected to the outlet. The material support 13 has a support section 131, on which multiple flow holes 1311 are uniformly formed. The material 800 is wound around the support section 131. That is, supercritical carbon dioxide enters the tubular structure through the outlet and inlet, and then flows uniformly through the flow holes 1311 on the support section 131 to the inner layer of material 800, and then permeates layer by layer to the outer layer of material 800. During this flow process, dissolved dye enters the material 800 and adheres, thereby completing the dyeing of the material 800.

[0080] Optionally, the tubular structure is coaxially arranged with the box 121, that is, the fluid flowing out from the output pipe 1211 can directly enter the tubular structure while maintaining the same flow direction. This is beneficial to ensure that the fluid flow at the flow holes 1311 at all points along the circumference of the support section 131 is relatively balanced, and to ensure that the dyeing concentration of the material 800 is more balanced at all points.

[0081] Optionally, the tubular structure is detachably connected to the box 121, facilitating the removal of the original dye box 121 from the tubular structure and the installation of the new dye box 121 during color changes. Optionally, one end of the tubular structure with an inlet has an assembly tube 132 protruding outward along its own axial direction, and the output tube 1211 is inserted into the assembly tube 132. Optionally, in this embodiment, the output tube 1211 is inserted into the assembly tube 132. To ensure sealing, a second sealing ring 133 is fitted onto the output tube 1211 and sandwiched between the output tube 1211 and the assembly tube 132. Optionally, a second limiting groove is formed on the inner wall of the assembly tube 132, and the second sealing ring 133 is located within the second limiting groove to prevent the second sealing ring 133 from shifting.

[0082] Optionally, the box body 121 is detachably connected to the dyeing kettle 11 to ensure that the box body 121 has a fixed position inside the dyeing kettle 11 and to facilitate the removal of the box body 121 and replacement with a new box body 121. Optionally, in this embodiment, the box body 121 is snapped into the dyeing kettle 11, and a positioning ring is protruding from the inner wall of the dyeing kettle 11. The positioning ring is coaxially arranged with the dyeing kettle 11, and a positioning groove is provided on the outer wall of the box body 121. The positioning ring is made of elastic material, and the box body 121 can move along the axial direction of the dyeing kettle 11 inside the dyeing kettle 11 until the positioning ring is inserted into the positioning groove.

[0083] Optionally, the tubular structure is detachably connected to the dyeing vessel 11. The dyeing vessel 11 can support the tubular structure and the material 800 on it, ensuring that it is located on the axis of the dyeing vessel 11. The detachable connection facilitates the removal of the tubular structure, making it easier to wind and remove the material 800. Optionally, a bracket can be provided on the outer wall of the second sealing end of the tubular structure. The bracket can abut against the bottom of the inner wall of the dyeing vessel 11 to support the tubular structure.

[0084] Optionally, in some embodiments, the tubular structure can rotate around its own axial direction, which can increase the fluid velocity and improve the uniformity of the fluid flow rate along the circumferential direction. Optionally, the tubular structure rotates synchronously with the dye support tube 122, or the dye support tube 122 does not rotate, but the tubular structure and the dye support tube 122 are relatively rotated and sealed together, which can be achieved by setting a sealed bearing or other structure. Optionally, the driving component for driving the rotation of the tubular structure can be a motor, which can be set inside the dyeing kettle 11 or outside the dyeing kettle 11, and then the output end of the motor and the tubular structure are connected through a transmission structure such as a transmission shaft.

[0085] Optionally, the dyeing system includes M dyeing units 1, where M is a positive integer greater than 1. Each dyeing unit 1 includes a dyeing kettle 11, a dye box 12, and a material support 13 disposed within the dyeing kettle 11. In this embodiment, M is 2. In other embodiments, M may also be a positive integer of 3, 4, 5, 6, 7, or larger. The appropriate number of dyeing units 1 can be set according to actual specifications and requirements.

[0086] like Figure 3 As shown, optionally, the dyeing system also includes a storage tank 2. The inlet 111 of the dyeing vessel 11 of each dyeing unit 1 is connected to the outlet of the storage tank 2, and the outlet 112 of the dyeing vessel 11 of each dyeing unit 1 is connected to the inlet of the storage tank 2. The storage tank 2 is used to store carbon dioxide and can also pressurize and heat the carbon dioxide to achieve a supercritical state.

[0087] Optionally, each dyeing unit 1 includes a pressure boosting valve 14, which is located on the pipeline between the output end and the input port 111. Optionally, each dyeing unit 1 includes a pressure relief valve 15, which is located on the pipeline between the output port 112 and the input end.

[0088] Optionally, each dyeing unit 1 further includes a circulation pipeline 16, one end of which is connected to the pipeline between the pressure boosting valve 14 and the inlet 111, and the other end of which is connected to the pipeline between the outlet 112 and the pressure relief valve 15. Each circulation pipeline 16 is equipped with a circulation pump 17 to provide power for fluid circulation. Optionally, the circulation pump 17 can be a magnetic pump, a plunger pump, or other high-pressure resistant pump.

[0089] Optionally, each circulation pipeline 16 is also equipped with a filter 18, which can completely filter and retain the oligomers precipitated from the material 800 under high temperature and high pressure conditions. Optionally, the filter 18 can be installed downstream of the dyeing kettle 11 or integrated inside the dye box 12.

[0090] Optionally, each circulation pipeline 16 is also equipped with a flow meter 19. By monitoring the flow meter 19 in real time, the cumulative flow rate of the fluid in circulation can be calculated, and the dyeing process can be estimated, which facilitates the control of the dyeing process.

[0091] Optionally, each circulation pipe 16 is also equipped with an exhaust valve 110 to facilitate exhaust and pressure relief.

[0092] Optionally, after carbon dioxide flows out from the outlet 112 of the dyeing vessel 11, it passes sequentially through the exhaust valve 110, the filter 18, the circulation pump 17, and the flow meter 19. It is known that the filter 18 is located before the circulation pump 17 to prevent impurities from damaging the circulation pump 17.

[0093] Optionally, a recovery pump 4 is installed on the inlet pipeline of storage tank 2 to provide power during carbon dioxide recovery. Optionally, a booster pump 3 is installed on the outlet pipeline of storage tank 2 to provide power during carbon dioxide output.

[0094] When only the pressure boosting valve 14 is opened, carbon dioxide can be introduced into the dyeing vessel 11 and the circulation pipeline 16. When both the pressure boosting valve 14 and the pressure relief valve 15 are closed, turning on the circulation pump 17 can achieve stable circulation within the dyeing unit 1. The flow rate of carbon dioxide can also be adjusted by regulating the circulation pump 17 to ensure uniform dyeing. When only the pressure relief valve 15 is opened, carbon dioxide can be depressurized and recovered.

[0095] In this embodiment, the volume of a dyeing vessel 11 can reach 3000L-5000L. By arranging multiple dyeing vessels 11 in parallel, such as configuring 2-4 dyeing units 1 in a single storage tank 2, a production capacity of 800kg-1000kg per batch can be achieved.

[0096] This dyeing system pre-loads dye evenly onto multiple porous loading layers, integrating it with a modular, novel, and uniformly distributed housing 121. Dye release ceases when carbon dioxide circulation stops. Actual measurements show a dye residue rate of less than 0.5%, an improvement of 10%-15% compared to traditional processes. Furthermore, the system's short-path design effectively reduces cooling and filtration processes, eliminating pipeline heat loss. Actual measurements show a heat loss rate reduced from 35% to below 8%, and energy consumption per ton of fabric reduced from 120 kWh to 60 kWh, achieving an energy saving rate of 50%. By using a cylindrical dye support tube 122 and winding the dye around it, the uniformity of dye dissolved in carbon dioxide is effectively improved, eliminating color difference factors at the core dye release step. Actual measurements show a color difference of no more than 0.5 grade, color fastness reaching 4-5 grades, and a first-pass dyeing success rate of no less than 98%. Moreover, by installing a filter 18 within the dyeing unit 1, the oligomer removal rate exceeds 95%, effectively preventing dyeing defects such as white spots, horizontal lines, and wavy patterns. The recovered carbon dioxide of this dyeing system no longer contains dye impurities. Compared with existing technologies, it eliminates the need for multi-stage cooling and filtration equipment, reducing equipment manufacturing costs by 40% and operation and maintenance costs by 30%. Moreover, the entire process achieves zero wastewater discharge, reducing the carbon emission intensity per ton step to 0.54t, while the traditional process is 2.1t, which shows a 74% reduction in carbon emission intensity.

[0097] It should be noted that in this embodiment, the dyeing medium of the dyeing system is supercritical carbon dioxide. In other embodiments, other suitable fluid media may also be applicable. Furthermore, the material 800 to be dyed by this dyeing system can be common fibers such as polyester and cotton, or special materials such as aramid, feather fiber, and PLA polylactic acid fiber.

[0098] This dyeing system employs an innovative design that integrates modular, wound dye cartridges within the dyeing autoclave. This achieves precise dye delivery (controllable dye uptake per cycle in cyclic dyeing), minimal system integration, and a significant reduction in dyeing energy consumption. Furthermore, through simulation calculations and comparative studies with actual operating conditions, iterative optimization of system control can be achieved, enhancing the energy efficiency and automation level of this supercritical anhydrous dyeing system. This further reduces equipment manufacturing costs, increases dyeing production efficiency, lowers operating costs, and increases net profit margins, laying the foundation for large-scale industrial application and promotion.

[0099] This dyeing system not only overcomes the technical challenges of large-scale industrial application of existing supercritical carbon dioxide dyeing methods, but also achieves low-energy dyeing with supercritical carbon dioxide, realizing the goal of green, low-carbon, and environmentally friendly supercritical carbon dioxide anhydrous dyeing. This system reduces costs associated with electricity, gas, auxiliaries, and pollution control, while simultaneously improving the production efficiency, first-pass dyeing yield, and colorfastness of fabrics. Considering the entire dyeing process, the dye (single-cycle dyeing) is precisely controllable, and the dye residue in the carbon dioxide penetrating the fabric is almost zero, enabling the repeated recycling of carbon dioxide. This ensures consistent color quality across batches of dyed fabric, further enhancing the long-term reliability of the equipment and significantly reducing the dyeing cost per kilogram of fabric and the equipment manufacturing cost.

[0100] like Figure 4 As shown, this embodiment also provides a method of use, applied to the staining system described above. The method includes a preparation stage, an injection stage, a staining stage, and a recovery stage.

[0101] Preparation stage: First, the carbon dioxide in storage tank 2 is preheated until it reaches specific temperature and pressure conditions. Simultaneously, based on the dyeing requirements of material 800, the dye loading is calculated, and the corresponding dye layer 123 is wound onto the dye support tube 122 according to the dye loading.

[0102] Theoretically, the amount of dye applied in a single application X satisfies: X = A × B × N × k, where k is a preset release efficiency coefficient, usually greater than 98%, A is the total effective area of ​​a porous loading layer, B is the dye loading per unit area, and N is the total number of porous loading layers.

[0103] Therefore, the number of porous load layers N can be calculated based on the single dyeing amount X, the total effective area A of a porous load layer, and the dye loading per unit area B in the dyeing requirements. N = X / (A × B × k), where k is the preset release efficiency coefficient mentioned above, and the value of k can be obtained through experimental testing. It should be noted that since dye is uniformly distributed between the innermost porous load layer and the dye support tube 122, and dye is uniformly distributed between any two adjacent porous load layers, the number of dye layers is consistent with the number of porous load layers. Therefore, the above calculation formula directly uses the number of porous load layers.

[0104] The above method can be used to determine how many layers of a specific porous loading layer are needed for a specific dyeing requirement. By simply controlling the number of layers, the target dye loading can be achieved.

[0105] After the dye layer 123 is wound, the dye support tube 122 and the box body 121 can be assembled. First, open the back cover of the box body 121, insert the dye support tube 122 into the box body 121, ensure that the connecting tube 1222 is located in the guide tube 1212, connect the positioning part of the dye support tube 122 to the outer wall of the box body 121 with screws, and then close the back cover of the box body 121.

[0106] After assembling the dye support tube 122 and the box body 121, the dye box 12 and the material support component 13 can be assembled. The output tube 1211 of the dye box 12 is inserted into the assembly tube 132 of the material support component 13, ensuring a sealed connection between the two to obtain a complete dyeing module. Finally, the dyeing module is placed into the dyeing kettle 11, and the positioning groove is inserted into the positioning ring to ensure the dyeing module is fixed relative to the dyeing kettle 11. The kettle lid is then closed, completing the step of assembling the dyeing module into the dyeing kettle 11.

[0107] Injection Phase: Open the pressure boosting valve 14 of each dyeing unit 1, keep the pressure relief valve 15 closed, and start the booster pump 3 to inject carbon dioxide into each dyeing unit 1. The carbon dioxide will flow from the storage tank 2 into each dyeing unit 1 and gradually fill the dye support pipe 122, material support 13, and circulation pipeline 16 until the carbon dioxide reaches a supercritical state. Optionally, in this embodiment, when the carbon dioxide pressure reaches the process set pressure of 23 MPa, the pressure boosting valve 14 of each dyeing unit 1 can be closed, and then the booster pump 3 can be turned off. At this time, the supercritical carbon dioxide fills the dyeing kettle 11 and circulation pipeline 16 of each dyeing unit 1.

[0108] Dyeing stage: The circulation pump 17 of each dyeing unit 1 is turned on, and supercritical carbon dioxide flows through the dyeing kettle 11 and circulates. The circulation time is controlled according to the cumulative circulation flow rate of supercritical carbon dioxide and the dyeing depth requirements of material 800. Since pressure and temperature affect the solubility of supercritical carbon dioxide, the actual dyeing amount can be controlled by adjusting the pressure or temperature of carbon dioxide.

[0109] In this process, supercritical carbon dioxide flows unidirectionally under the action of circulating pump 17. The supercritical carbon dioxide enters the dyeing kettle 11, dissolves with the dye in the dye box 12, and then carries the dissolved dye into the material support 13, evenly penetrating the rolled fabric through the flow holes 1311. When the supercritical carbon dioxide penetrates the fabric, the fabric and dye form a tight adsorption bond, thus dyeing the fabric. Driven by the circulating pump 17, the fluid forms a strong flow field, ensuring that carbon dioxide can evenly penetrate the fabric from the inner cavity of the material support 13 through the flow holes 1311, achieving a uniform dyeing effect. The supercritical carbon dioxide gas that has penetrated no longer carries dye and enters the filter 18. The filter element of the filter 18 completely filters and retains the oligomers precipitated from the fabric under high temperature and high pressure conditions, thereby fundamentally solving the technical problem affecting the dyeing efficiency of supercritical carbon dioxide. Under the action of circulating pump 17, the above dyeing cycle is continuously repeated. After a certain period of time, all the dye in the dye box 12 can be absorbed by the fabric, completing the dyeing process. Then, continue the cycle for a period of time to achieve color fixation.

[0110] Optionally, during this process, the controller uses a PID control algorithm to adjust the operating power of the circulating pump 17 according to the real-time flow rate measured by the flow meter 19, so as to regulate the flow rate of the fluid and achieve precise control of dye release.

[0111] Recovery Stage: Supercritical carbon dioxide is depressurized and recovered. After color fixing is complete, the depressurization valve 15 of each dyeing unit 1 is opened, and the recovery pump 4 is started simultaneously. The supercritical carbon dioxide, which is under high temperature and high pressure (temperature 95℃-110℃, pressure approximately 23MPa-25MPa), is directly recovered into the storage tank 2 for reuse. When the pressure in the circulation pipeline 16 drops to 0.5MPa, the exhaust valve 110 of the corresponding dyeing unit 1 is opened until the pressure in the dyeing kettle 11 reaches zero. The dyeing kettle 11 is then opened, and the dyeing module, i.e., the dye box 12 and the material support 13, is pulled out together. At this point, dyeing unit 1 has completed one dyeing operation.

[0112] It should be noted that different staining units 1 can be controlled independently according to different staining needs. The above description of a uniform action is for ease of understanding. In actual use, different staining units 1 can maintain different staining paces to achieve different staining needs.

[0113] By applying the above-described method to the dyeing system, manufacturing and maintenance costs can be reduced, dyeing efficiency can be improved, and the first-pass dyeing yield can be increased. Experimental results show that, using this method, the dye utilization rate approaches 100%, the amount of dye applied in a single cycle can be precisely controlled, system energy consumption is reduced by more than 50%, equipment manufacturing costs are reduced by more than 40%, and large-scale industrial dyeing with batches ranging from 800kg to 5000kg can be achieved.

[0114] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A dyeing system, characterized in that The dyeing system comprises: a dyeing kettle (11) having an input port (111) and an output port (112); a dye box (12) arranged in the dyeing kettle (11), the dye box (12) comprising a box body (121), a dye support pipe (122) and a dye layer (123), the dye support pipe (122) having a flow inlet and a first blocking end along two ends of the dye support pipe (122) in the axial direction, the flow inlet being communicated with the input port (111), the dye support pipe (122) being partially arranged in the box body (121), the dye support pipe (122) having a ventilation section, the first blocking end and the ventilation section being located in the box body (121), a plurality of ventilation holes (1221) being uniformly arranged on the side wall of the ventilation section, the dye layer (123) being wound on the ventilation section, the dye layer (123) comprising a porous support layer and dyes uniformly arranged on the porous support layer, the box body (121) comprising a flow outlet, the flow outlet being communicated with a collection space (125) between the box body (121) and the ventilation section; a material support (13) arranged in the dyeing kettle (11), the material support (13) being used for supporting a material (800); the dyeing system is configured so that a dyeing medium can flow through the input port (111), the flow inlet, the ventilation holes (1221), the dye layer (123), the collection space (125), the flow outlet, the material (800) and the output port (112) in sequence, so that the dyeing medium can dissolve and carry the dyes to dye the material (800).

2. The dyeing system according to claim 1, characterized in that, The porous support layer is a molecular film, a plurality of flow-through holes are uniformly arranged on the molecular film, and the pore diameter of the flow-through holes is greater than the particle size of the dissolved disperse dyes. And / or, the undissolved dyes are in a granular structure, and the pore diameter of the flow-through holes is smaller than the minimum size of the granular structure.

3. The dyeing system according to claim 1, characterized in that, A plurality of layers of the porous support layer are wound on the ventilation section from the inside to the outside, and the dyes are uniformly arranged between any two adjacent layers of the porous support layer; And / or, the cross section of the dye support pipe (122) is circular or regular polygonal; And / or, the flow outlet is coaxially arranged with the dye support pipe (122); And / or, the box body (121) is coaxially arranged with the dye support pipe (122); And / or, the dye support pipe (122) can rotate around the axial direction thereof.

4. The dyeing system according to claim 1, characterized in that, The material support (13) is in a tubular structure, the tubular structure having a filling inlet and a second blocking end along two ends of the tubular structure in the axial direction, the filling inlet being communicated with the flow outlet, the material support (13) having a support section (131), a plurality of flow-through holes (1311) being uniformly arranged on the side wall of the support section (131), and the material (800) being wound on the support section (131).

5. The dyeing system according to claim 4, characterized in that, The tubular structure is coaxially arranged with the box body (121); And / or, the tubular structure is detachably connected with the box body (121). And / or, the box body (121) is detachably connected with the dyeing kettle (11); And / or, the tubular structure is detachably connected with the dyeing kettle (11); And / or, the tubular structure is capable of rotating around its own axis.

6. The dyeing system according to claim 4, characterized in that, The dyeing system comprises M dyeing units (1), M being a positive integer greater than 1, each of the dyeing units (1) comprising the dyeing kettle (11) and the dye box (12) and the material support (13) arranged in the dyeing kettle (11).

7. The dyeing system according to claim 6, characterized in that The system further comprises a storage tank (2), the input port (111) of the dyeing kettle (11) of each of the dyeing units (1) being communicated with the output end of the storage tank (2), and the output port (112) of the dyeing kettle (11) of each of the dyeing units (1) being communicated with the input end of the storage tank (2).

8. The dyeing system according to claim 7, characterized in that Each of the dyeing units (1) comprises a booster valve (14) arranged on the pipeline between the output end and the input port (111); And / or, each of the dyeing units (1) comprises a pressure relief valve (15) arranged on the pipeline between the output port (112) and the input end.

9. The dyeing system according to claim 8, characterized in that, Each of the dyeing units (1) further comprises a circulation pipeline (16) having one end communicated with the pipeline between the booster valve (14) and the input port (111) and the other end communicated with the pipeline between the output port (112) and the pressure relief valve (15), and a circulation pump (17) arranged on each of the circulation pipelines (16); Each of the circulation pipelines (16) is further provided with a filter (18), a flow meter (19) and / or an exhaust valve (110).

10. Use according to claim 9, characterized in that, The use method is applied to the dyeing system according to any one of claims 1-9 and comprises the following steps: A preparation stage: according to the dyeing requirements of the material (800), the load of the dye is calculated, the corresponding dye layer (123) is wound on the dye support pipe (122) according to the load of the dye, the dye support pipe (122) is assembled with the box body (121), the dye box (12) is assembled with the material support (13) to obtain a dyeing module, and the dyeing module is assembled into the dyeing kettle (11); An injection stage: carbon dioxide is injected into each dyeing unit (1) until the carbon dioxide is in a supercritical state; A dyeing stage: the supercritical carbon dioxide flows through the dyeing kettle (11) and circulates, and the circulation time is controlled according to the cumulative circulation flow of the supercritical carbon dioxide and the dyeing depth requirement of the material (800); A recovery stage: the supercritical carbon dioxide is depressurized and recovered.

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