Apparatus and process for dyeing of a textile material

Abstract

An apparatus (100) and a method for spray application of a dye solution onto a textile material (105) including a first spray station (200) configured to spray the dye solution onto a first side of the textile material (105), a second spray station (210) configured to spray the dye solution onto a second side of the textile material (105), opposite to the first side, and a control system (220) configured to control the first spray station (200) to deliver a first amount of the dye solution and the second spray station (210) to deliver a second amount of the dye solution, wherein the first amount is different from the second amount.

Description

Field

[0001] The technology relates to the field of textile dyeing and processing, specifically to spray application of dye solutions onto textile materials for achieving uniform and controlled coloration.Background

[0002] Dyeing of textile materials is a crucial process in the textile industry, as it imparts desired features such as color, glaze, water-repellence, flame resistance, and softness to the materials. The dye is a substance that chemically bonds to the substrate, such as the textile material, and is typically held in a liquid that forms a dye solution, like water in an aqueous solution. The dyeing process generally involves an application or impregnation stage, where the dye solution is applied to the textile material, followed by a fixation stage and a drying phase, where the liquid is removed from the material.

[0003] Conventional dyeing processes, where the textile material is submerged in the dyeing liquid, require substantial amounts of liquid, which can lead to increased water consumption and energy usage. An alternative method is dyeing by spray application in the impregnation stage, which offers benefits in terms of reduced liquid consumption and energy conservation.

[0004] However, a challenge associated with spray application is achieving even application of the dye on the textile material. Uneven application can result in inhomogeneity in the desired features across the material's surface, such as color, leading to cloudy or uneven effects. This inconsistency can be attributed to areas with higher or lower concentrations of dye, causing uneven color, glaze, or other unpreferred features. Therefore, there is a need for an improved dyeing process that ensures uniformity in the desired features across the textile material's surface while maintaining the benefits of spray application in terms of liquid consumption and energy conservation.Summary

[0005] According to a first aspect of the disclosure, an apparatus is provided for the spray application of a dye solution onto a textile material. The apparatus comprises a first spray station configured to spray the dye solution onto a first side of the textile material, a second spray station configured to spray the dye solution onto a second side of the textile material, opposite to the first side, and a control system configured to control the first spray station to deliver a first amount of the dye solution and the second spray station to deliver a second amount of the dye solution, wherein the first amount is different from the second amount. This allows for a more precise and controlled application of dye to the textile material, improving the quality and consistency of the final product. Specifically, evenness in obtainment of the dye in the textile material has been improved, for instance in color dyeing. Notably, this configuration of the apparatus has been shown to minimize occurrence of cloud effects in the finished dyed textile material.

[0006] Optionally in some examples, the apparatus further comprises a conveyor system configured to convey the textile material from the first spray station to the second spray station. This allows for a continuous and efficient process of dye application, reducing the time and effort required in manual handling of the textile material.

[0007] Optionally in some examples, the conveyor system comprises a first application roller facing the first spray station and a second application roller facing the second spray station, the first and second application rollers acting as backrests for the textile material upon spray application. This ensures that the textile material is properly positioned and supported during the dye application process, enhancing the uniformity and quality of the dye application.

[0008] Optionally in some examples, the second spray station is arranged downstream of the first spray station in a propagation direction of the textile material through the apparatus. This arrangement allows for a sequential application of dye to the two sides of the textile material, ensuring that the dye is evenly and thoroughly applied.

[0009] Optionally in some examples, the control system is configured to control the first amount and the second amount in relation to a combined amount delivered to the textile material by the first spray station and the second spray station. This allows for a precise control of the total amount of dye applied to the textile material, ensuring a consistent and high-quality dyeing result.

[0010] Optionally in some examples, the first amount is 55-70% of the combined amount. This specific ratio ensures an optimal balance between the amounts of dye applied to the two sides of the textile material, enhancing the overall quality and appearance of the dyed textile material. In some examples, the first amount is 65+ / -5% of the combined amount. The combined amount corresponds to a total pickup of the dye solution.

[0011] Optionally in some examples, the first side of the textile material is an intended front side of a garment. This allows for a more targeted application of dye to the more visible side of a garment. Notably, improvement in counteracting cloud effects in color on the intended front side of the garment has been obtained for where the textile material is a cut open tubular knitted fabric, such as T-shirt fabric, where the first side of the textile material is a convex outside surface of the cut open tubular knitted fabric.

[0012] Optionally in some examples, the first amount is controlled to be larger than the second amount. This allows for a more intense dyeing of the first side of the textile material, which can be desirable in certain applications where a more pronounced color effect is desired on one side of the textile material. Alternatively, the second amount is controlled to be larger than the first amount.

[0013] According to a second aspect of the disclosure, a method is provided for using an apparatus for spraying a dye solution onto a textile material. The method comprises conveying the textile material to a first spray station, spraying a first amount of the dye solution onto a first side of the textile material using the first spray station, conveying the textile material to a second spray station, and spraying a second amount of the dye solution onto a second side of the textile material, opposite to the first side, using the second spray station, wherein the first amount is controlled to be different from the second amount. This method allows for a precise and controlled application of dye to the textile material, improving dye homogeneity of the final product.

[0014] Optionally in some examples, the method further comprises controlling the first amount and the second amount in relation to a combined amount delivered to the textile material by the first spray station and the second spray station. This allows for a precise control of the total amount of dye applied to the textile material, ensuring a consistent and high-quality dyeing result.

[0015] Optionally in some examples, the first amount is 55-70% of the combined amount. This specific ratio ensures an optimal balance between the amounts of dye applied to the two sides of the textile material, enhancing the overall quality and appearance of the dyed textile material. In some examples, the first amount is 65+ / -5% of the combined amount. The combined amount corresponds to a total pickup of the dye solution.

[0016] Optionally in some examples, the first side of the textile material is an intended front side of a garment. This allows for a more targeted application of dye to the more visible side of a garment, enhancing its aesthetic appeal.

[0017] Optionally in some examples, the textile material is a cut open tubular knitted fabric. This allows for a more efficient and thorough application of dye to the textile material, as the cut open tubular knitted fabric provides a larger surface area for dye application.

[0018] Optionally in some examples, the first side of the textile material is a convex outside surface of the cut open tubular knitted fabric, and the second side is a concave inner surface of the cut open tubular knitted fabric. Particularly notable improvement in dye homogeneity has been obtained upon spray dyeing of such a fabric, wherein the higher first amount of dye solution is first sprayed onto the outside surface, followed by the lower second amount being sprayed onto the inner surface.Brief Description of the Drawings

[0019] Examples are described in more detail below with reference to the appended drawings. Figure 1 is a schematic representation of an apparatus 100 for dyeing a textile material 105, showing the conveyor system 110, first spray station 200, second spray station 210, and a dye supply system 230. Figure 2 is a detailed view of the control system 220, illustrating its connection to the spray stations of the apparatus. Figure 3 is an example of a nozzle system 240, which may be included in the spray stations, showing the components and their connections. Figure 4 is a schematic of an example of a representation of the arrangement of the conveyor system 110 and the spray stations 200, 210, demonstrating the positioning of the application rollers and a downward propagation direction of the textile material 105. Figure 5 is a flow chart of a method for dyeing a textile material by spraying, outlining the steps involved in using the apparatus 100. Detailed Description

[0020] The detailed description set forth below provides information and examples of the disclosed technology with sufficient detail to enable those skilled in the art to practice the disclosure.

[0021] Figure 1 illustrates an exemplary embodiment of the apparatus 100 for spray application of a dye solution onto a textile material 105. The apparatus 100 is designed to facilitate the even application of dye onto the textile material 105, thereby enhancing the quality and consistency of the dyeing process. The apparatus 100 includes several components, each of which plays a role in the dyeing process. These components include a first spray station 200, a second spray station 210, a control system 220, a dye supply system 230, and a conveyor system 110. Each of these components is designed to work in harmony with the others to ensure the efficient and effective application of dye onto the textile material 105.

[0022] In one implementation, the apparatus 100 includes a first spray station 200 and a second spray station 210, each of which is configured to spray the dye solution 233 onto the textile material 105. The apparatus 100 also includes a control system 220, which is configured to control the operation of the first spray station 200 and the second spray station 210. The apparatus 100 further includes a dye supply system 230, which supplies the dye solution 233 to the first spray station 200 and the second spray station 210. Finally, the apparatus 100 includes a conveyor system 110, which transports the textile material 105 through the apparatus 100.

[0023] In some examples, the textile material 105 is a cut open tubular knitted fabric. The textile material 105 has a first side 106 and a second side 107. The first side 106 is the convex outside surface of the cut open tubular knitted fabric, and the second side 107 is the concave inner surface of the cut open tubular knitted fabric. The textile material 105 is designed to receive the dye solution 233 from the first spray station 200 and the second spray station 210. The textile material 105 is transported through the apparatus 100 by the conveyor system 110, which ensures that the textile material 105 is properly positioned for the application of the dye solution 233. The textile material 105 is designed to absorb the dye solution 233, resulting in a dyed textile material with a consistent and uniform color. The textile material 105 may be used in the manufacture of a variety of products, including clothing, upholstery, and other textile-based products. The textile material 105 is, as such, not part of the apparatus 100.

[0024] In some configurations, the apparatus 100 includes a motor mechanism 111. The motor mechanism 111 is designed to drive the conveyor system 110, enabling the transportation of the textile material 105 through the apparatus 100. The motor mechanism 111 may be electrically powered and may be configured to operate continuously or in a stepwise manner. The motor mechanism 111 may be connected to one or more rollers of the conveyor system 110, and its operation may result in the rotation of these rollers. The rotation of the rollers, in turn, moves the textile material 105 from the first spray station 200 to the second spray station 210. The motor mechanism 111 is controlled by the control system 220, which can adjust the speed and direction of the motor mechanism 111 to ensure the optimal application of the dye solution 233 onto the textile material 105.

[0025] In one example, the apparatus 100 includes a further processing station 112. The processing station 112 is designed to perform further processing on the textile material 105 after it has been dyed by the first spray station 200 and the second spray station 210. The processing station 112 may include various components and systems for performing operations such as fixing or drying the dye on the textile material 105. The processing station 112 may also include systems for inspecting the dyed textile material 105 to ensure that the dye has been applied evenly and consistently. The proposed solution is not, as such, dependent on the processing station 112 which is therefore not described in further detail.

[0026] In some implementations, the first spray station 200 is configured to spray the dye solution 233 onto the first side 106 of the textile material 105. The first spray station 200 includes a nozzle system 240, which includes at least one spray nozzle 241. The spray nozzle 241 is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The first spray station 200 also includes a valve mechanism 242, which is configured to control the amount of dye solution 233 that is ejected by the spray nozzle 241. The first spray station 200 is controlled by the control system 220, which can adjust the operation of the first spray station 200 to deliver a first amount of dye solution 233 onto the textile material 105.

[0027] In one configuration, the second spray station 210 is arranged downstream of the first spray station 200 in the propagation direction of the textile material 105 through the apparatus 100. The second spray station 210 is configured to spray the dye solution 233 onto the second side 107 of the textile material 105, which is opposite to the first side 106. Like the first spray station 200, the second spray station 210 includes a nozzle system that sprays the dye solution 233 onto the textile material 105. The second spray station 210 is controlled by the control system 220, which can adjust the operation of the second spray station 210 to deliver a second amount of dye solution 233 onto the textile material 105. The second amount of dye solution 233 may be different from the first amount, allowing for the application of different amounts of dye on the first side 106 and the second side 107 of the textile material 105.

[0028] In some examples, the nozzle system 240 is a component of both the first spray station 200 and the second spray station 210. The nozzle system 240 includes at least one spray nozzle 241, a valve mechanism 242, a conduit 243, and a connector 244. The spray nozzle 241 is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The valve mechanism 242 is configured to control the amount of dye solution 233 that is ejected by the spray nozzle 241. The conduit 243 leads the dye solution 233 from the connector 244 to the spray nozzle 241. The connector 244 connects the nozzle system 240 to the dye supply system 230. The nozzle system 240 also includes a control input interface 245, which is communicatively connected to the control interface 222 of the control system 220. The control input interface 245 receives control signals from the control interface 222, which are used to control the valve mechanism 242.

[0029] In one implementation, the dye supply system 230 is responsible for supplying the dye solution 233 to the first spray station 200 and the second spray station 210. The dye supply system 230 includes a container 231 and a pump 232. The container 231 holds the dye solution 233, while the pump 232 supplies the dye solution 233 from the container 231 to the first spray station 200 and the second spray station 210. The dye supply system 230 is designed to ensure a consistent supply of dye solution 233 to the spray stations, thereby facilitating the even application of dye onto the textile material 105.

[0030] In one example, the pump 232 is a component of the dye supply system 230 and is responsible for supplying the dye solution 233 from the container 231 to the first spray station 200 and the second spray station 210. The pump 232 may be a positive displacement pump, a centrifugal pump, or any other type of pump suitable for pumping the dye solution 233. The pump 232 is controlled by the control system 220, which can adjust the operation of the pump 232 to ensure the optimal supply of dye solution 233 to the first spray station 200 and the second spray station 210.

[0031] In some implementations, the dye solution 233 is a mixture of dye and a solvent, such as water. The dye solution 233 is designed to be sprayed onto the textile material 105 by the first spray station 200 and the second spray station 210. The dye in the dye solution 233 is absorbed by the textile material 105, with the intention to obtain a dyed textile material with a consistent and uniform dye quality, such as color. The dye solution 233 may include various types of dyes, including reactive dyes, direct dyes, acid dyes, basic dyes, or any other type of dye suitable for dyeing the textile material 105. The dye solution 233 may also include various additives, such as fixatives, leveling agents, or other chemicals designed to enhance the dyeing process.

[0032] Figure 2 provides a detailed view of the control system 220 in one example of the apparatus 100. The control system 220 is a component of the apparatus 100, as it is responsible for controlling the operation of the first spray station 200 and the second spray station 210. The control system 220 is designed to ensure that the dye solution 233 is applied to the textile material 105 in a controlled and precise manner, thereby enhancing the quality and consistency of the dyeing process. The control system 220 includes a control unit 221 and a control interface 222, each of which plays a role in the operation of the control system 220.

[0033] In some configurations, the control system 220 is designed to be user-friendly, with controls and interfaces that are intuitive and easy to operate. The control system 220 is also designed to be robust and reliable, capable of withstanding the rigors of a high-volume textile dyeing operation. The control system 220 includes a control unit 221, which is responsible for controlling the operation of the first spray station 200 and the second spray station 210. The control system 220 also includes a control interface 222, which provides control signals from the control unit 221 to the first spray station 200 and the second spray station 210. The control system 220 is configured to control the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210.

[0034] In one implementation, the control unit 221 comprises logic circuitry of the control system 220. The control unit 221 is responsible for processing input signals from various sensors and interfaces, and generating control signals for the first spray station 200 and the second spray station 210, and optionally also the dye supply system 230 and the conveyor system 110. The control unit 221 may include a microprocessor, a microcontroller, a programmable logic controller (PLC), or any other type of processing device suitable for controlling the operation of the apparatus 100. The control unit 221 may also include memory for storing control programs, sensor data, and other information necessary for the operation of the apparatus 100.

[0035] In some examples, the control interface 222 is a component of the control system 220 that provides control signals from the control unit 221 to the first spray station 200 and the second spray station 210. The control interface 222 may include various types of interfaces, such as digital interfaces, analog interfaces, wireless interfaces, or any other type of interface suitable for transmitting control signals. The control interface 222 may also include a user interface, such as a display, a keypad, a touchscreen, or any other type of user interface suitable for allowing a user to interact with the control system 220. The control interface 222 is designed to ensure that the control signals from the control unit 221 are accurately and reliably transmitted to the first spray station 200 and the second spray station 210.

[0036] Figure 3 provides a detailed view of the nozzle system 240 in one configuration of the apparatus 100. Both the first spray station 200 and the second spray station 210 comprise a respective nozzle system, both of which may be configured in accordance with the nozzle system 240 of Figure 3. The nozzle system 240 is responsible for spraying the dye solution 233 onto the textile material 105. The nozzle system 240 includes at least one spray nozzle 241, and possibly an array of nozzles, and a valve mechanism 242 connected to the / each nozzle 241. The nozzle system 240 may further comprise a conduit 243 and a connector 244. Each of these components plays a role in the operation of the nozzle system 240.

[0037] In some implementations, the nozzle system 240 is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The nozzle system 240 includes at least one spray nozzle 241, which is designed to spray the dye solution 233 onto the textile material 105. The nozzle system 240 also includes a valve mechanism 242, which is configured to control the amount of dye solution 233 that is ejected by the spray nozzle 241. The nozzle system 240 further includes a conduit 243, which leads the dye solution 233 from the connector 244 to the spray nozzle 241. The connector 244 connects the nozzle system 240 to the dye supply system 230. The nozzle system 240 also includes a control input interface 245, which is communicatively connected to the control interface 222 of the control system 220. The control input interface 245 receives control signals from the control interface 222, which are used to control the valve mechanism 242.

[0038] The spray nozzle 241 may be a flat spray nozzle, a full cone nozzle, a hollow cone nozzle, or any other type of nozzle suitable for spraying the dye solution 233 onto the textile material 105. The spray nozzle 241 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity. The spray nozzle 241 may also include a filter or a strainer to prevent particles or impurities in the dye solution 233 from clogging the nozzle.

[0039] In some configurations, the nozzle system 240 includes a valve mechanism 242. The valve mechanism 242 is configured to control the amount of dye solution 233 that is ejected by the spray nozzle 241. The valve mechanism 242 may an impulse valve, a solenoid valve, a pneumatic valve, a hydraulic valve, or any other type of valve suitable for controlling the flow of the dye solution 233. The valve mechanism 242 may be controlled by the control system 220, which can adjust the operation of the valve mechanism 242 to ensure the optimal application of the dye solution 233 onto the textile material 105.

[0040] In one implementation, the nozzle system 240 includes a conduit 243. The conduit 243 is designed to lead the dye solution 233 from the connector 244 to the spray nozzle 241. The conduit 243 may be a pipe, a tube, a hose, a hole drilled in a nozzle housing, or any other type of conduit suitable for transporting the dye solution 233. The conduit 243 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity. The conduit 243 may also include a filter or a strainer to prevent particles or impurities in the dye solution 233 from reaching the spray nozzle 241.

[0041] In some examples, the nozzle system 240 includes a connector 244. The connector 244 is designed to connect the nozzle system 240 to the dye supply system 230. The connector 244 may be a quick-connect fitting, a threaded fitting, a flanged fitting, or any other type of fitting suitable for connecting the nozzle system 240 to the dye supply system 230. The connector 244 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity.

[0042] In one configuration, the nozzle system 240 includes a control input interface 245. The control input interface 245 is communicatively connected to the control interface 222 of the control system 220. The control input interface 245 is designed to receive control signals from the control interface 222, which are used to control the valve mechanism 242. The control input interface 245 may include various types of interfaces, such as digital interfaces, analog interfaces, wireless interfaces, or any other type of interface suitable for receiving control signals.

[0043] Figure 4 provides a detailed view of the conveyor system 110 in one example of the apparatus 100. The conveyor system 110 is designed to transport the textile material 105 through the apparatus 100, from the first spray station 200 to the second spray station 210. The conveyor system 110 includes a first application roller 115, a second application roller 116, a spreader roller 113, and a first guide roller 114. Each of these components plays a role in the operation of the conveyor system 110.

[0044] In some implementations, the conveyor system 110 is designed to transport the textile material 105 through the apparatus 100 in a controlled and precise manner. The conveyor system 110 includes a first application roller 115 and a second application roller 116, which act as backrests for the textile material 105 upon spray application. The conveyor system 110 also includes a spreader roller 113, which engages the second side of the textile material 105 and stretches the textile material laterally upon rotating, to inhibit creasing or folding of the textile material 105. The conveyor system 110 further includes a first guide roller 114, which propagates the textile material 105 from the spreader roller 113, via the first guide roller, to the first application roller 115. The conveyor system 110 is driven by the motor mechanism 111, which is controlled by the control system 220 to ensure the optimal transportation of the textile material 105 through the apparatus 100.

[0045] In one example, the conveyor system 110 includes a spreader roller 113. The spreader roller 113 is designed to engage the second side 107 of the textile material 105 and stretch the textile material laterally upon rotating. This lateral stretching of the textile material 105 helps to inhibit creasing or folding of the textile material 105, thereby ensuring that the dye solution 233 is applied evenly onto the textile material 105. The spreader roller 113 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity. The spreader roller 113 may also include a surface texture or a coating designed to enhance its grip on the textile material 105, thereby improving the effectiveness of the lateral stretching operation.

[0046] In some configurations, the conveyor system 110 includes a first guide roller 114. The first guide roller 114 is designed to propagate the textile material 105 from the spreader roller 113 to the first application roller 115. The first guide roller 114 ensures that the textile material 105 is properly positioned for the application of the dye solution 233 by the first spray station 200. The first guide roller 114 may include a surface texture or a coating designed to enhance its grip on the textile material 105, thereby improving the effectiveness of the propagation operation.

[0047] In one implementation, the conveyor system 110 includes a first application roller 115. The first application roller 115 acts as a backrest for the textile material 105 upon spray application using the first spray station 200. The first application roller 115 ensures that the textile material 105 is properly positioned for the application of the dye solution 233 by the first spray station 200. The first application roller 115 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity. The first application roller 115 may also include a surface texture or a coating designed to enhance its grip on the textile material 105, thereby improving the effectiveness of the spray application operation.

[0048] In some examples, the conveyor system 110 includes a second application roller 116. The second application roller 116 acts as a backrest for the textile material 105 upon spray application using the second spray station 210. The second application roller 116 ensures that the textile material 105 is properly positioned for the application of the dye solution 233 by the second spray station 210. The second application roller 116 may be made of a material that is resistant to the corrosive effects of the dye solution 233, ensuring its longevity. The second application roller 116 may also include a surface texture or a coating designed to enhance its grip on the textile material 105, thereby improving the effectiveness of the spray application operation.

[0049] The second application roller 116 is arranged downstream of the first application roller 115, in the propagation direction of the textile material 105. In some examples, the second application roller 116 is arranged immediately after the first application roller 115, as shown in the drawing.

[0050] Figure 5 provides a detailed view of the method of using the apparatus 100 for spraying a dye solution onto a textile material 105. The method includes several steps, each of which plays a role in the dyeing process. In the broadest perspective, the method comprises spraying 505 a first amount of dye solution 233 onto a first side 106 of the textile material 105 using the first spray station 200 and spraying 515 a second amount of dye solution 233 onto a second side 107 of the textile material 105 using the second spray station 210, wherein the first amount is controlled to be different from the second amount.

[0051] Where the method involves spray application in successive steps, the steps of the method may comprise conveying 500 the textile material 105 to the first spray station 200, spraying 505 a first amount of dye solution 233 onto a first side 106 of the textile material 105 using the first spray station 200, conveying 510 the textile material 105 to the second spray station 210, and spraying 515 a second amount of dye solution 233 onto a second side 107 of the textile material 105 using the second spray station 210. The method may also include controlling the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210.

[0052] In one implementation, the method of using the apparatus 100 for spraying a dye solution onto a textile material 105 includes several steps. First, the textile material 105 is conveyed 500 to the first spray station 200. This step is facilitated by the conveyor system 110, which transports the textile material 105 through the apparatus 100. Second, the first spray station 200 sprays 505 a first amount of dye solution 233 onto a first side 106 of the textile material 105. This step is controlled by the control system 220, which adjusts the operation of the first spray station 200 to deliver the first amount of dye solution 233. Third, the textile material 105 is conveyed 510 to the second spray station 210. This step is also facilitated by the conveyor system 110. Fourth, the second spray station 210 sprays 515 a second amount of dye solution 233 onto a second side 107 of the textile material 105. This step is also controlled by the control system 220, which adjusts the operation of the second spray station 210 to deliver the second amount of dye solution 233. In some examples, the control system 220 controls the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210. By way of example, a certain percentage of the total combined amount is controlled to be delivered by the first spray station 200, whereas a complementary percentage (adding up to 100%) of the total combined amount is controlled to be delivered by the second spray station 200. The first 200 and second 210 spray stations may be configured, by the control system 220, to deliver relative percentages of the combined amount of between 70 / 30 and 55 / 45, or in a narrower configuration between 65 / 35 and 55 / 45. This step ensures that the dye solution 233 is applied to the textile material 105 in a controlled and precise manner, thereby enhancing the quality and consistency of the dyeing process.

[0053] In some examples, the first step of the method involves conveying the textile material 105 to the first spray station 200. This step is facilitated by the conveyor system 110, which is designed to transport the textile material 105 through the apparatus 100 in a controlled and precise manner. The conveyor system 110 includes a first application roller 115, a second application roller 116, a spreader roller 113, and a first guide roller 114. Each of these components plays a role in the operation of the conveyor system 110. The first application roller 115 acts as a backrest for the textile material 105 upon spray application using the first spray station 200, ensuring that the textile material 105 is properly positioned for the application of the dye solution 233.

[0054] In one configuration, the conveyor system 110 plays a role in the transportation of the textile material 105 through the apparatus 100. The conveyor system 110 is designed to move the textile material 105 from the first spray station 200 to the second spray station 210 in a controlled and precise manner. The conveyor system 110 includes a motor mechanism 111, which drives the conveyor system 110 and enables the transportation of the textile material 105 through the apparatus 100. The motor mechanism 111 may be electrically powered and may be configured to operate continuously or in a stepwise manner. The motor mechanism 111 is controlled by the control system 220, which can adjust the speed and direction of the motor mechanism 111 to ensure the optimal application of the dye solution 233 onto the textile material 105.

[0055] In some implementations, the second step of the method involves spraying a first amount of dye solution 233 onto a first side 106 of the textile material 105 using the first spray station 200. This step is controlled by the control system 220, which adjusts the operation of the first spray station 200 to deliver the first amount of dye solution 233. The first spray station 200 includes a nozzle system 240, which includes at least one spray nozzle 241. The spray nozzle 241 is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner.

[0056] In one example, the first spray station 200 is a component of the apparatus 100. The first spray station 200 is configured to spray the dye solution 233 onto the first side 106 of the textile material 105. The first spray station 200 includes a nozzle system 240, which includes at least one spray nozzle 241. The spray nozzle 241 is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The first spray station 200 is controlled by the control system 220, which can adjust the operation of the first spray station 200 to deliver a first amount of dye solution 233 onto the textile material 105.

[0057] In some configurations, the control system 220 is responsible for determining and controlling the first amount of dye solution 233 that is sprayed onto the first side 106 of the textile material 105 by the first spray station 200. The control system 220 includes a control unit 221 and a control interface 222, each of which plays a role in the operation of the control system 220. The control unit 221 is responsible for processing input signals from various sensors and interfaces, and generating control signals for the first spray station 200. The control interface 222 provides control signals from the control unit 221 to the first spray station 200, which are used to control the amount of dye solution 233 that is sprayed onto the textile material 105.

[0058] In one implementation, the third step of the method involves conveying the textile material 105 to the second spray station 210. This step is also facilitated by the conveyor system 110, which is designed to transport the textile material 105 through the apparatus 100 in a controlled and precise manner. The conveyor system 110 includes a second application roller 116, which acts as a backrest for the textile material 105 upon spray application using the second spray station 210, ensuring that the textile material 105 is properly positioned for the application of the dye solution 233.

[0059] In some examples, the conveyor system 110 plays a role in the transportation of the textile material 105 through the apparatus 100. The conveyor system 110 is designed to move the textile material 105 from the first spray station 200 to the second spray station 210 in a controlled and precise manner. The conveyor system 110 includes a motor mechanism 111, which drives the conveyor system 110 and enables the transportation of the textile material 105 through the apparatus 100. The motor mechanism 111 is controlled by the control system 220, which can adjust the speed and direction of the motor mechanism 111 to ensure the optimal application of the dye solution 233 onto the textile material 105.

[0060] In one configuration, the fourth step of the method involves spraying a second amount of dye solution 233 onto a second side 107 of the textile material 105 using the second spray station 210. This step is also controlled by the control system 220, which adjusts the operation of the second spray station 210 to deliver the second amount of dye solution 233. The second spray station 210 includes a nozzle system, which includes at least one spray nozzle. The spray nozzle is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The second amount of dye solution 233 may be different from the first amount, allowing for the application of different amounts of dye on the first side 106 and the second side 107 of the textile material 105.

[0061] In some examples, the second spray station 210 is a component of the apparatus 100. The second spray station 210 is configured to spray the dye solution 233 onto the second side 107 of the textile material 105, which is opposite to the first side 106. The second spray station 210 includes a nozzle system, which includes at least one spray nozzle. The spray nozzle is designed to spray the dye solution 233 onto the textile material 105 in a controlled and precise manner. The second spray station 210 is controlled by the control system 220, which can adjust the operation of the second spray station 210 to deliver a second amount of dye solution 233 onto the textile material 105.

[0062] In one configuration, the control system 220 is responsible for determining and controlling the second amount of dye solution 233 that is sprayed onto the second side 107 of the textile material 105 by the second spray station 210. The control system 220 includes a control unit 221 and a control interface 222, each of which plays a role in the operation of the control system 220. The control unit 221 is responsible for processing input signals from various sensors and interfaces, and generating control signals for the second spray station 210. The control interface 222 provides control signals from the control unit 221 to the second spray station 210, which are used to control the amount of dye solution 233 that is sprayed onto the textile material 105.

[0063] In some implementations, the fifth step of the method involves controlling the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210. This step is facilitated by the control system 220, which is designed to ensure that the dye solution 233 is applied to the textile material 105 in a controlled and precise manner, thereby enhancing the quality and consistency of the dyeing process.

[0064] In one example, the control system 220 plays a role in managing the amounts of dye solution 233 that are sprayed onto the textile material 105 by the first spray station 200 and the second spray station 210. The control system 220 includes a control unit 221 and a control interface 222, each of which plays a role in the operation of the control system 220. The control unit 221 is responsible for processing input signals from various sensors and interfaces, and generating control signals for the first spray station 200 and the second spray station 210. The control interface 222 provides control signals from the control unit 221 to the first spray station 200 and the second spray station 210, which are used to control the amounts of dye solution 233 that are sprayed onto the textile material 105.

[0065] In some configurations, the control system 220 is responsible for calculating and adjusting the combined amount of dye solution 233 that is delivered to the textile material 105 by the first spray station 200 and the second spray station 210. The control system 220 uses input signals from various sensors and interfaces to calculate the combined amount of dye solution 233. The control system 220 then adjusts the operation of the first spray station 200 and the second spray station 210 to deliver the calculated combined amount of dye solution 233 onto the textile material 105. This ensures that the dye solution 233 is applied to the textile material 105 in a controlled and precise manner, thereby enhancing the quality and consistency of the dyeing process.

[0066] In one implementation, the method involves applying different amounts of dye solution 233 on the first side 106 and the second side 107 of the textile material 105. This is facilitated by the control system 220, which adjusts the operation of the first spray station 200 and the second spray station 210 to deliver different amounts of dye solution 233 onto the first side 106 and the second side 107 of the textile material 105. This allows for the application of different amounts of dye on the first side 106 and the second side 107 of the textile material 105, thereby enhancing the quality and consistency of the dyeing process.

[0067] In some examples, the first side 106 of the textile material 105 is an intended front side of a garment. In such cases, the control system 220 may be configured to deliver a larger amount of dye solution 233 onto the first side 106 of the textile material 105. This has been shown to provide optimum dye homogeneity on the first side 106, thereby enhancing quality and potentially the aesthetic appeal of the garment.

[0068] In one configuration, the textile material 105 is a cut open tubular knitted fabric. In such cases, the first side 106 of the textile material 105 is the convex outside surface of the cut open tubular knitted fabric, and the second side 107 is the concave inner surface of the cut open tubular knitted fabric. The control system 220 may be configured to deliver different amounts of dye solution 233 onto the first side 106 and the second side 107 of the textile material 105, thereby ensuring that the dye is applied evenly and consistently onto the textile material 105.

[0069] In some implementations, the method involves controlling the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210. This is facilitated by the control system 220, which is designed to ensure that the dye solution 233 is applied to the textile material 105 in a controlled and precise manner, thereby enhancing the quality and consistency of the dyeing process. This control of the first amount and the second amount of the dye solution 233 helps to achieve dye homogeneity on the textile material 105 and counteract cloud effects.

[0070] In one example, the control system 220 employs various strategies for distributing the dye solution 233 onto the textile material 105. For instance, the control system 220 may be configured to deliver a larger amount of dye solution 233 onto the first side 106 of the textile material 105, which is the intended front side of a garment. Alternatively, the control system 220 may be configured to deliver a larger amount of dye solution 233 onto the second side 107 of the textile material 105, which is the concave inner surface of a cut open tubular knitted fabric. Selected configuration may be dependent on the intended use of the textile material, such which of the first 106 and second 107 sides will be used as intended front or outer side of a textile product manufactured using the dyed textile material 105.

[0071] In some configurations, the control of the first amount and the second amount of the dye solution 233 in relation to a combined amount delivered to the textile material 105 by the first spray station 200 and the second spray station 210 has a significant impact on the final appearance of the textile material 105. For instance, delivering a larger amount of dye solution 233 onto the first side 106 of the textile material 105 can result in a garment with a rich and vibrant front side. On the other hand, delivering a larger amount of dye solution 233 onto the second side 107 of the textile material 105 can result in a textile material with a consistent and uniform color. Furthermore, controlling the first amount and the second amount of the dye solution 233 can help to counteract cloud effects, thereby enhancing the overall quality of the dyed textile material 105.

[0072] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof.

[0073] It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure.

[0074] Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.

[0075] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0076] It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

1. An apparatus (100) for spray application of a dye solution onto a textile material (105), the apparatus comprising: a first spray station (200) configured to spray the dye solution onto a first side of the textile material (105); a second spray station (210) configured to spray the dye solution onto a second side of the textile material (105), opposite to the first side; and a control system (220) configured to control the first spray station (200) to deliver a first amount of the dye solution and the second spray station (210) to deliver a second amount of the dye solution, wherein the first amount is different from the second amount.

2. The apparatus (100) according to claim 1, further comprising a conveyor system (110) configured to convey the textile material (105) from the first spray station (200) to the second spray station (210).

3. The apparatus (100) according to claim 2, wherein the conveyor system (110) comprises a first application roller (115) facing the first spray station (200) and a second application roller (116) facing the second spray station (210), the first and second application rollers (115, 116) acting as backrests for the textile material (105) upon spray application.

4. The apparatus (100) according to any one of claims 1 to 3, wherein the second spray station (210) is arranged downstream of the first spray station (200) in a propagation direction of the textile material (105) through the apparatus (100).

5. The apparatus (100) according to any one of claims 1 to 4, wherein the control system (220) is configured to control the first amount and the second amount in relation to a combined amount delivered to the textile material (105) by the first spray station (200) and the second spray station (210).

6. The apparatus (100) according to claim 5, wherein the first amount is 55-70% of the combined amount.

7. The apparatus (100) according to any one of claims 1 to 6, wherein the first side (106) of the textile material (105) is an intended front side of a garment.

8. The apparatus (100) according to any one of claims 1 to 7, wherein the first amount is larger than the second amount.

9. The apparatus (100) according to any one of claims 1 to 7, wherein the second amount is larger than the first amount.

10. A method of using an apparatus for spraying a dye solution onto a textile material, the method comprising: spraying (510) a first amount of the dye solution onto a first side of the textile material using a first spray station; spraying (520) a second amount of the dye solution onto a second side of the textile material, opposite to the first side, using a second spray station, wherein the first amount is controlled to be different from the second amount.

11. The method according to claim 10, further comprising controlling the first amount and the second amount in relation to a combined amount delivered to the textile material by the first spray station and the second spray station.

12. The method according to claim 11, wherein the first amount is 55-70% of the combined amount.

13. The method according to any one of claims 10 to 12, wherein the first side of the textile material is an intended front side of a garment.

14. The method according to any one of claims 10 to 13, wherein the textile material is a cut open tubular knitted fabric, wherein the first side of the textile material is a convex outside surface of the cut open tubular knitted fabric, and the second side is a concave inner surface of the cut open tubular knitted fabric.

15. The method according to any one of claims 10-14, further comprising: conveying (500) the textile material to the first spray station; and conveying (515) the textile material to the second spray station.

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