Method and apparatus for digital textile printing

Abstract

To provide a method and an apparatus for digitally controlled application and fixation of dyestuff to a textile on a processing line.SOLUTION: The method comprises the steps of: determining one or more parameters of a textile; determining, by a processor, at least one dose setting for an array of flow channel dispensers of the processing line, wherein determining the at least one dose setting is based on the one or more parameters; dispensing, by the array of flow channel dispensers, dyestuff onto the textile according to the at least one dose setting; detecting, by at least one sensor, an area of textile surface containing a colour inconsistency; correcting the detected inconsistency; and delivering energy to the textile to fix the dyestuff in the textile.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method and apparatus for dispensing dye onto textile substrates, and in particular to a process design for textile dyeing using an array of independently digitally controlled flow dispensers and fixation energy sources on the processing line that eliminates wastewater generation from washout and reduces energy costs. [Background technology]

[0002] Precision coating or dyeing is achieved through digital control of the flow path dispenser orifices, whereby the 2D and 3D distribution of industrial dye liquor can be controlled to within a few percent of the target value. This principle of precision application of dye liquor is applicable to many industrial materials. The technique utilizes control of liquid application along with control of ambient airflow to achieve a homogenous three-dimensional distribution of liquid dye within the textile material.

[0003] Precision adhesion is achieved through digital control of energy application using an energy source such as an infrared radiator, whereby the 2D and 3D distribution of energy can be controlled to achieve adhesion within a few percent of the target value.

[0004] Currently, textile coating or dyeing is an environmentally damaging process, primarily due to the generation of significant amounts of wastewater, usually several times the weight of the textile. Traditional processes for dye application are bath immersion methods such as exhaustion or jet dyeing and padding using roller application mechanisms. All traditional methods generally overdose excess dye onto the textile material, which must be removed via repeated high temperature washing, generating large amounts of polluted wastewater.

[0005] Contaminated wastewater, including water contaminated with dyes, is a significant worldwide environmental problem and requires comprehensive wastewater treatment to avoid environmental damage. Traditionally, bath immersion coating or dyeing is done to allow absorption of the dye into the fiber surface. The coating or dye may be nearly insoluble in water and may require time and high temperatures to adsorb onto the fiber surface and diffuse into the fiber, or react with the fiber to become trapped or chemically bonded. Alternatively, the coating or dye may be applied to the textile through a roller "padding" process. The applied dye is then dried and heated to fix the dye. For both of these traditional dyeing methods, washing is required to remove excess unbound dye and auxiliary chemicals. Washing usually involves several baths operated at high temperatures and may introduce additional chemicals, for example in a "reduction wash" process where a basic pH is used.

[0006] The new industrial process disclosed herein for textile dyeing, which does not require a washing step, contrasts with this background. The process is based on a precise three-dimensional distribution of only the required amount of dye and energy on the textile substrate, without the need for excessive dye application to achieve a dyed and fixed material. The disclosed approach allows for a major change in the industry's sustainability strategy through the elimination, or at least a dramatic reduction, of wastewater generated through the washing process. Summary of the Invention [Means for solving the problem]

[0007] In accordance with the present invention, there is provided a method for digitally controlled application and fixation of dyes to textiles on a processing line, the method comprising the steps of determining one or more parameters of the textiles and, by a processor, calculating at least one of the parameters for an array of flow path dispensers on the processing line. The method includes determining at least one dose setting, wherein determining the at least one dose setting is based on one or more parameters; dispensing dye onto the fabric according to the at least one dose setting by an array of flow path dispensers; and transmitting energy to the fabric to fix the dye within the fabric.

[0008] Further, the method may include the steps of determining one or more parameters of the textile to be dyed, determining by the processor at least one dose setting for an array of flow path dispensers of the processing line, wherein determining the at least one dose setting is based on the one or more parameters, and dispensing dye onto the textile by the array of flow path dispensers in accordance with the at least one dose setting.

[0009] The method may also include a digitally controlled drying step setting determined by the processor based on one or more parameters of the fabric to be dyed and one or more parameters of the dye application dosage setting.

[0010] Furthermore, the method may also include a digitally controlled setting of the fixing process, determined by the processor based on one or more parameters of the textile to be dyed and one or more parameters of the dye application dose setting.

[0011] Digital control of the array of channel dispensers can provide versatility such as real-time or near real-time color mismatch correction and / or near instantaneous color changeover on the same processing line. For example, application of dye to a textile via an array of channel dispensers allows deposition of precisely the correct dose of dye according to measured parameters of the textile, rather than the traditional method of immersing the textile in a disperse dye bath.

[0012] Application of energy for fixation using methods that allow digital input to control the power and distribution of the applied energy, e.g., infrared, UV, radio frequency, or microwave, to allow precise dosing of energy. This is in contrast to conventional bath and continuous dyeing processes where excessive energy is typically applied to achieve fixation.

[0013] For example, application of dye to textiles via an array of liquid dispensers, rather than the traditional method of immersing textiles in a disperse dye bath, may allow deposition of precisely the correct dose of dye according to the textile's absorption capacity, which may be determined based on measured parameters of the textile to be dyed. This entails a huge reduction in the amount of wasted resources, such as water to disperse the dye, excess dye required to ensure a concentration gradient, and energy required for subsequent washing after fixation.

[0014] Additionally, digital control of the liquid dispenser and energy emission sources for fixing provides added versatility such as mismatch correction and near instantaneous color changeover on the same processing line.

[0015] Determining the one or more parameters may include at least one of receiving a data input including the one or more parameters and detecting the one or more parameters using one or more sensors. The input parameters may be provided by the textile manufacturer or by preliminary offline evaluation / testing. This allows precise and controlled parameter details to be obtained in a custom environment.

[0016] The detection of the textile parameters using sensors eliminates the risk of human error when entering and recording the textile parameters and the possibility of errors arising due to incorrect labelling of the textile. Reduce the possibility of

[0017] Fabric parameters can be detected in real-time or near real-time on the processing line, thus allowing real-time or near real-time detection of inconsistencies or errors in the fabric, which allows dye and energy dose settings to be rapidly and independently adjusted by a processor and / or prevents continuous lengths of suboptimal or inconsistent fabric from being dyed.

[0018] The one or more parameters may include at least one of: fabric basis weight, fabric absorption capacity, fabric moisture content, fabric speed through the system, dye concentration, fabric thickness, fabric diameter, fabric batch code; color; shade; Pantone; reflectance, and any other fabric surface optical properties. Determining the one or more parameters may occur before the fabric is dyed, while the fabric is dyed, and / or after the fabric is dyed. This approach allows for multiple parameters to be measured throughout the process. Comparisons between parameters measured at different points along the processing line may also be made by the processor to optimize dose settings. This may improve the quality of the final product. For example, in configurations where both sides of the fabric are not dyed simultaneously, the determination of the parameters may occur after the first side of the fabric is dyed but before the second side of the fabric is dyed. Because the dye penetrates the fabric, the appearance of the first side of the fabric may be altered when the second side of the fabric is dyed. As a result, the dose setting for the second side may take into account the appearance of the first side after the dyeing of the second side.

[0019] In one embodiment, the method includes determining one or more parameters of a textile to be dyed. Determining the parameters of the fabric before it is dyed, i.e., the fabric to be dyed, allows for precise selection of dosage settings to reflect the parameters of the fabric to be dyed, thus improving the quality and consistency of the dyed fabric. Determining the parameters of the fabric before it is dyed also reduces wasted dye and fabric that can result from calibrating a channel dispenser every time a new fabric is used.

[0020] In one embodiment, the method includes the step of continuously determining one or more parameters of a textile fabric to be dyed. Continuously determining the parameters of the fabric before it is dyed allows for independent adjustment of dose settings and / or flow path dispensers in real time or near real time, so that intermittent inconsistencies or variations in the fabric can be adjusted and correct dose settings can be specified across the entire array of flow path dispensers.

[0021] The dose settings may include at least one of dye color, dye concentration and amount, and / or dye flow rate. The amount of dye to be dispensed onto the fabric can be less than or equal to the saturation absorbent capacity of the fabric, the saturation absorbent capacity being determined based at least in part on one or more parameters.

[0022] Alternatively, the amount of dye to be dispensed onto the fabric may exceed the saturation absorbent capacity of the fabric, the saturation absorbent capacity being determined based at least in part on one or more parameters. The dose setting may be determined based at least in part on the target shade.

[0023] The step of dispensing may further include a feedback step, in response to detecting, by the at least one sensor, an area of ​​the textile surface containing a color mismatch, to correct the detected mismatch.

[0024] Correcting the detected mismatch may allow adjustments in dye or energy dosing to prevent future Inconsistencies in the second application of dye may be prevented. Alternatively or additionally, the mismatched fabric may be re-fed onto the processing line to correct any mismatches during the second application of dye. If both sides of the fabric are dyed separately, the dose setting for the second side may be changed to compensate for the sensed condition of the first side of the fabric.

[0025] Having feedback and correction mechanisms in the same process line also eliminates the need for additional quality checking and correction equipment, reducing the overall complexity of the process line equipment and the time it takes to get to a finished product.

[0026] The color mismatch may be across the length of the fabric, i.e. the mismatch varies over time. Alternatively or additionally, the color mismatch may be across the width of the fabric, i.e. the mismatch is consistent over time.

[0027] Correcting the detected misalignment may include controlling the flow of the atomized liquid dye using an airflow by a processor to deflect the dispensed dye to compensate for primed areas of the fabric surface.

[0028] Alternatively or additionally, the processor may be used to dye a two-dimensional defined shape to remove dye in areas of the textile that are not intended to be used in the final product. This process may be performed with a double-sided registration mark on both sides of the double-sided application. Dispensing the dye into at least one separate location on the textile reduces the amount of dye required. The dispensing location may be approximately similar to the desired final product for the textile, and thus any location or area of ​​the textile that is known not to require dye may be left undyed. Undyed textile may be more easily recycled or reused. These locations may include locations that will be offcuts and / or may include locations that will not be visible in the final product.

[0029] The at least one distinct location may be determined by a processor. Further, the at least one distinct location may be a predetermined shape. The shape may cover an entire width and / or length of the textile. Alternatively, the shape may not cover an entire width and / or length of the textile. The shape may be a shape of a garment.

[0030] The method may include determining, by a processor, an optimal or near-optimal layout of the distinct locations configured to maximize a surface area of ​​the textile to be dyed, the layout including at least one distinct location of the textile to be dyed.

[0031] The layout may include a plurality of distinct locations of the textile to be dyed. Each distinct location may be identical. Alternatively or additionally, each distinct location may be different. The distinct locations may differ in at least one of shape, size, color, and form. The layout may include a combination of identical distinct locations and different distinct locations.

[0032] An optimal layout may include two or more tessellated shapes. A near-optimal layout minimizes the total area of ​​undyed fabric. The method may further include determining, by the processor, at least one continuous boundary between the locations of the dyed fabric and the locations of the undyed fabric, and isolating, by a separation module, the portion of the dyed fabric enclosed within the boundary.

[0033] The separated portions of the dyed textile may be completely dyed. The separated portions of the dyed textile may be approximately the same shape as the separate locations of the dyed textile. Alternatively or additionally, the separated portions of the dyed textile may be smaller than the locations of the dyed textile.

[0034] The separation module may include a cutting mechanism such as a guillotine or punch. The method may further include determining, by the processor, at least one continuous boundary between the locations of dyed fabric and the locations of undyed fabric, and isolating, by the separation module, a portion of the fabric that includes the entirety of the at least one boundary.

[0035] Separating the portion of the fabric including the entire border ensures that the remaining fabric is either completely dyed or completely undyed. This allows the dyed fabric to be further processed as required and allows the undyed fabric to be recycled or reused.

[0036] The separated portion that includes the boundary may also include a strip of fabric surrounding the boundary, and the strip may be of a predetermined width. Separating the strip surrounding the boundary ensures that the remaining fabric is fully dyed or fully undyed. The predetermined width of the strip may be less than 1000, 500, 250, 100, 50, 25, 10, 5, 3, or 1 millimeter (mm). The predetermined width may be determined in real time or near real time by the processor. Alternatively or additionally, the predetermined width may be an input of the processor.

[0037] The end result of both applying the dye and performing the fixing under digital control is that it is possible to produce dyed and fixed materials that do not require washing to meet typical industry standards.

[0038] The dye application process can be accomplished by spraying, inkjet printing, or, most preferably, an array of independently controlled channel dispensers that produce an atomized spray of liquid dye that is transported using an air stream.

[0039] The array of channel dispensers may be configured with the dispensing tips of the channel dispensers in close proximity to the textile substrate to achieve a substantially uniform application of the liquid dye to the textile. The channel dispenser may be configured with the dispensing tip of the channel dispenser at a distance of between 5mm and 50mm from the fabric surface.

[0040] The array of channel dispensers may include two sub-arrays of channel dispensers that dispense dye onto both sides of the fabric. The array of channel dispensers may provide significant overlap in dispensing area to achieve redundancy and dose averaging.

[0041] Most preferably, the air stream is arranged to be directed against the side of the fabric opposite the dye application. The processor may independently control each of the flow path dispensers. Each individual dispensing element within the array of flow path dispensers may be turned on and off by the processor. Additionally, the amount of dye being dispensed by each flow path dispenser may also be controlled by the processor.

[0042] Independent control of each channel dispenser allows for precise, localized adjustment of the dye being dispensed. This allows for accurate and consistent target shades to be achieved even when the fabric being dyed has inconsistencies. Furthermore, localized inconsistencies within the dyed fabric can be prevented.

[0043] The fluid dispensing tip may be in the form of an ultrasonic atomizer nozzle. The dispensed dye flow rate is a function of fluid pressure, nozzle duty cycle, ultrasonic energy, The pumps may be controlled using at least one of positive displacement pumping, each of which may be controlled by a processor.

[0044] The dye dispensed from the flow channel dispenser is -1 The spray may be in the form of spray droplets with a velocity exceeding . The spray droplets may have an average diameter in the range of 1 to 50 microns.

[0045] Airflow can be in the range of 50-500 kg hr-1 per metre width. Spray droplets moving at a velocity primarily perpendicular to the substrate were determined to sufficiently penetrate industrial fabrics so as not to require an additional adsorption step.

[0046] The method may further include detecting the inconsistencies in the textile and controlling, by the processor, at least one of the jetting frequency of one or more of the fluid dispensers, the airflow applied to the dispensed dye to adjust the flow rate, the trajectory of the dispensed dye, and the power emitted by the energy source to compensate for the detected inconsistencies. Digitally controlled variations in the throughput liquid dispensers and the applied airflow provide a universal and instantaneous mechanism for implementing correction of defects in the dyeing of textiles, all on the same processing line.

[0047] Detecting inconsistencies in the fabric to be dyed allows each of the channel dispensers to be adjusted accordingly, thus producing a more consistent, homogenous dyed fabric. Additionally, inconsistencies can also be detected in the dyed fabric, and using a feedback mechanism, the dye or energy dose settings can be adjusted accordingly to prevent the inconsistency from reoccurring.

[0048] The method may further include detecting an inconsistency in the array of flow path dispensers and controlling, by the processor, an airflow directed at at least one or more of the flow path dispensers and / or the dye being dispensed to adjust a flow rate or trajectory of the dye being dispensed to compensate for the detected inconsistency.

[0049] Inconsistencies within an array of channel dispensers, such as varying dye flow rates, can be due to blockages, partial blockages, and / or air bubbles within the dosing elements. Alternatively, the method may include detecting an inconsistency in an array of fluid dispensers and pausing the processing line entirely with a processor.

[0050] Identification of an error in the flow path dispenser may result in the processing line being shut down to prevent the continued production of substandard or inconsistent fabrics, thus saving both cost and time.

[0051] The method may further comprise a step of "bulk" fixing the dosed dye onto the textile. The fixing step may be performed by application of dry air or steam at a temperature in the range of 180° C. to 250° C. Alternatively or additionally, the fixing step may be performed by application of dry heat or steam together with application of radiation in the form of at least one of infrared, microwave, and radio frequency radiation.

[0052] The method may further include dispensing dye onto at least one discrete location of the fabric by an array of channel dispensers. Further, in accordance with the present invention, there may be provided an apparatus configured to carry out the disclosed method, the apparatus comprising a processing line for conveying a textile material, a processor, and an array of channel dispensers, each channel dispenser being independently controlled and conveyed by the processor. and an array of flow channel dispensers configured to dispense dye onto a surface of the fabric.

[0053] The apparatus may comprise sensing means for detecting one or more parameters of the conveyed textile and / or one or more inconsistencies and / or one or more boundaries between dyed and undyed textile.

[0054] The apparatus may further comprise a separation module for separating dyed and undyed portions of the fabric. The apparatus may further comprise fixing means for fixing the dispensed dye onto the transported textile.

[0055] The apparatus may further comprise a fabric unwinding module located at the beginning of the processing line and a fabric unwinding module at the end of the processing line. The method of the present disclosure is an industrial process for applying dye liquor to 2D or 3D fabrics, such as textiles and cloth, through a digitally controlled dosing system, with the advantage that the dye is delivered within the area of ​​the textile fabric's capacity for coating absorption. This can be done, for example, by detecting one or more parameters of the textile to be dyed, such as the textile weight, using a weight sensor. A processor then calculates the amount of dye and fixation energy required to achieve the target shade for the textile based on the measured parameters. Thus, the method described herein can be used to reduce the need for soaking baths and the need to wash excess coating from textiles.

[0056] The technical principle utilized by the present invention is the accurate measurement of the parameters of the fabric to be dyed and the determination by a processor of the dosage settings for the fabric based on the parameters, followed by the controlled application of dye from an array of channel dispensers to deposit exactly the right amount of dye on the fabric surface.

[0057] Thus, the disclosed digital dyeing process is either zero or low wastewater and enables a new manufacturing technology platform for on-demand digital dyeing of textiles. The technology eliminates or dramatically reduces wastewater discharge. The disclosed method also achieves manufacturing cost savings and profitability benefits, for example, by reducing minimum dyeing "run" lengths and enabling rapid changeover between different colors and textile materials.

[0058] The digital nature of the dosing control makes it possible to achieve a target dye shade on a single process line, for example in an arrangement where the fabric is unwound at the start of the process line and unwound at the end of the process line.

[0059] Benefits include elimination of wastewater due to precise dye dosing. Wastewater reduction is greater than 95% compared to traditional dye application methods. Reduction in dye usage is also possible as excess dye does not need to be applied to ensure the target shade is achieved, reducing the amount of dye and auxiliary chemicals required to dye a given fabric by up to 30%. The disclosed method also achieves a reduced carbon footprint and is up to 80% energy saving when compared to traditional methods.

[0060] Alternatively or additionally, the processor may determine one or more parameters of the dyed fabric and provide real-time or near real-time feedback corresponding to the dose setting. The processor may determine the quality, accuracy, and consistency of the dyed fabric and provide real-time or near real-time feedback to the dispenser. Real-time may mean less than 10 milliseconds. This may allow for adjustment of dosage settings, if necessary, and / or temporary pausing of dye dosing to prevent the production of significant lengths of defective or inconsistently dyed textile. Additionally, the digital nature of the disclosed process allows for on-demand dyeing of textiles and allows for precise target shades to be achieved on textile substrates. Conventional methods that require time-consuming textile pretreatment and steeping, and do not provide for digitally controlled shading of textiles, do not allow for on-demand dyeing.

[0061] Yet another advantage is that a platform utilizing the disclosed method can operate at a throughput of over 2000 square meters per hour, and is therefore suitable for high throughput industrial manufacturing environments.

[0062] The process can achieve excellent color matching across the textile web with a delta value of <0.5 variation through the use of an array of digitally controlled channel dispensers. The process is capable of precise color matching and shade control through digital control of applied volume and can be used with a wide range of fabrics.

[0063] Exemplary technical specifications for an apparatus configured to carry out the disclosed methods are given in Table 1.1.

[0064] [Table 1]

[0065] The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0066] [Figure 1] 1 is a flow diagram of an exemplary method according to the present invention. [Diagram 2] 1 is a detailed exemplary workflow flow diagram according to an embodiment of the disclosed method. [Diagram 3]1A-1D illustrate exemplary woven fibers at various stages of dye application. [Figure 4] FIG. 1 illustrates an exemplary apparatus for implementing the disclosed methods. [Diagram 5] 1A-1C illustrate exemplary configurations of a channel dispenser for dispensing dye onto a textile substrate. [Figure 6] FIG. 1 illustrates an exemplary processing line according to some embodiments of the present invention, comprising a first pass and a second pass. [Figure 7] 1 illustrates an exemplary configuration of a channel dispenser for dispensing dye onto a textile substrate with the addition of a vacuum chamber. [Figure 8] FIG. 1 illustrates an example woven fabric during application of dye on a first pass during a two pass processing line. [Figure 9] FIG. 2 illustrates an example of a drying stage within some embodiments of a processing line. [Figure 10] FIG. 1 illustrates an exemplary textile fabric during a drying stage within some embodiments of the processing line. [Figure 11] FIG. 1 shows an example of how the moisture content of a dye on a textile substrate can vary with time when a change in temperature is applied. [Figure 12] FIG. 1 illustrates an example of a fixation stage within some embodiments of a processing line. [Figure 13] 1 is a flow diagram of an exemplary method of the present invention. [Figure 14] FIG. 1 illustrates an exemplary processing line according to some embodiments of the present invention comprising at least one sensor. [Figure 15A] FIG. 1 illustrates an exemplary processing line in which dye is applied to a generally horizontal surface of a textile substrate. [Figure 15B] FIG. 1 illustrates an exemplary processing line in which dye is applied to substantially vertical surfaces of a woven fabric. [Figure 15C] FIG. 1 illustrates an embodiment of a processing line including a drum configured to determine a path for a textile fabric. [Figure 16] FIG. 2 illustrates an exemplary dye supply, circulation, and drainage system for a dosing element of the present invention. [Figure 17] FIG. 2 shows a dye supply, circulation and drainage system for a dosing element of the present invention with a header tank. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] In order to further explain various aspects of the present disclosure, specific embodiments of the present disclosure will now be described in detail, by way of example only and not by way of limitation, along with the accompanying drawings.

[0068] Referring to FIG. 1, an exemplary method according to the present invention includes determining 10 one or more parameters of a fabric being conveyed on a processing line. The determination may be made via user input, automatic input, or digital sensing of one or more sensors on the processing line equipment. Exemplary parameters that may be input or sensed are the weight of the fabric, typically between 50 and 500 gm. -2 the fabric basis weight, the fabric fiber denier / diameter, and the fabric weave type.

[0069] The illustrated method further includes a step 12 of determining at least one dose setting for the array of flow-channel dispensers based on the one or more parameters determined in the first step. The determination is performed by a processor 50, the processor being configured to control the array of flow-channel dispensers. In some embodiments, the array of flow-channel dispensers may comprise a portion of a print head configured to dispense dye.

[0070] Detection of the fabric parameters using sensors reduces the risk of human error when inputting / recording the fabric parameters and the inherent possibility of errors that may occur due to incorrect labelling of the fabric.

[0071] The conversion of one or more parameters into a dosage setting for the deposition of the dye liquor on the textile surface allows the deposition of the fluid according to the maximum absorption capacity of the textile transported on the processing line. This eliminates the need for excess fluid deposition on the textile surface to ensure that the target shade is achieved, allowing the deposition of exactly the right amount of dye with minimal subsequent washing required. The determined dosage setting is usually a mass flow rate per unit width (mL / min / m).

[0072] After the at least one dose setting is determined, the method comprises administering the at least one dose setting according to the at least one dose setting. For example, a dye liquor may be dispensed onto the fabric surface according to a dosage setting calculated to achieve a target color shade for the fabric.

[0073] In some embodiments, the method further includes a closed feedback loop for in-line correction of mismatches in the fabric that do not achieve the target color shade. For example, a color sensor can be used to detect color mismatches in the fabric and notify the processor 50. The color sensor can be a camera, or color sensing can be performed by fiber optic spectroscopy. With appropriate selection of sensor color match using LAB, values ​​up to an accuracy of delta e<0.5 can be achieved. Various methods can then be utilized to correct the detected mismatch, such as adjusting a digitally controlled channel dispenser by modifying the jetting frequency of the dispensed fluid or applying an airflow to deflect the dispensed fluid to compensate for the detected mismatch.

[0074] Digitally controlled variation of the liquid dispenser jetting frequency, the applied energy, and / or the applied airflow provides a versatile and instantaneous mechanism for effecting correction of defects in the dyeing of textiles, all on the same processing line.

[0075] Having feedback and correction mechanisms in the same processing line also reduces the complexity of the overall dyeing process and the time it takes to get to the finished product by eliminating the need for additional quality checks and post-dyeing correction equipment.

[0076] Referring to FIG. 2, an exemplary workflow for a single dyeing "run" of textile is shown. The fabric is unwound and fed onto the processing line and then in a parameter pretreatment stage 16 a parameter of the fabric is measured and sent to a processor 50. In this case the parameter determined is the basis weight of the fabric. The fabric is then pretreated by application of steam at 120° C. to ensure that the surface of the fabric is in a condition in which dye can be absorbed.

[0077] The next stage is a dye application stage 18, starting with an optional wash bath, followed by a second basis weight detection to calculate the amount of steam and water absorbed by the fabric. Based on the second basis weight detection, controlled drying of the fabric is performed until the fabric contains a target moisture content. Drying is performed by at least one of infrared (IR), near infrared (NIR), mid infrared (MIR), and microwave heating.

[0078] When the fabric is determined to be at the correct moisture content, dye is applied by a digitally controlled array of channel dispensers. Optionally, in-line color sensing and correction can be applied at this stage to ensure that a homogenous application of dye is achieved on the fabric surface. Further drying is then performed, followed by a final sensing step to determine moisture content and dye absorption. Drying is performed by at least one of infrared (IR) heating, near infrared (NIR) heating, mid-infrared (MIR) heating, and microwave heating. The final sensing step can include a further measurement of basis weight.

[0079] The final stage of the dye application process is the in-line fixation stage 20. Dye fixation is carried out via application of hot steam or dry heat of about 150-250° C. to the dyed fabric. Near instantaneous spatial fixation of the dye while the fabric is on the same processing line has the advantage of avoiding dye migration after dye application, a problem associated with conventional processes.

[0080] In some embodiments, the in-line bonding process also includes at least one of infrared (IR) heating, near infrared (NIR) heating, mechanical infrared (MIR) heating, and microwave heating. It may include one application.

[0081] Referring to FIG. 3, an exemplary woven fabric is shown during various stages of the dyeing process. In the first step of the process, the unmodified fiber 22 is measured, for example to determine the basis weight of the fabric. In the second step of the process, the fabric is pre-hydrated, optionally immersed in water, resulting in a fiber having an increased moisture content layer on its surface 24. In the third step of the process, a digitally controlled application of dye is applied to the fabric. Precision of dosing and deposition allows the dye to form a homogenous distribution over the surface of the pre-hydrated fiber 26. Finally, in the fourth step of the process, the dye is fixed to the fabric, the bond between the dye and the fiber 28 is strengthened, and the accumulated high moisture layer is dissipated and evaporated. Referring to FIG. 4, an exemplary processing line apparatus 29 for carrying out the disclosed method is shown.

[0082] The illustrated apparatus includes an unwind module 30 for unwinding a roll of fabric prior to loading onto a conveyor belt contained within a pretreatment, dyeing, and fixing enclosure 32. An array of digitally controlled flow dispensers 38 are contained within the enclosure 32, and several dye supply tanks 34 provide the dye liquor to be dispensed onto the transported fabric. Finally, at the end of the processing line, there is an unwind module 36 for unwinding the dyed and fixed fabric after the process is completed.

[0083] The flow path dispenser 38 is comprised of an array of independently controllable digital elements to allow for dosing variation along and across the web of fabric being transported. The dispenser is capable of delivering liquid dye at high speeds to completely penetrate the bulk of the fabric.

[0084] The array of channel dispensers 38 configured within the enclosure 32 can be configured as a single array or as two sub-arrays facing both sides of the transported textile. Channel dispensers configured with two sub-arrays have the advantage that dye can be dispensed simultaneously or sequentially onto both sides of the transported textile without the need for two separate transport steps for the textile. This allows for a more efficient dyeing process and less time is needed to perform each run.

[0085] The channel dispenser 38 used to carry out the disclosed method can be selected from several types. For example, the channel dispenser can be included in the print head configuration disclosed in WO 2017 / 187153, the contents of which are incorporated herein by reference. In other embodiments, a spray coater with a digitally controlled mass flow controller or a slot die coater with a digitally controlled mass flow controller of a digital inkjet print head is used.

[0086] The array of channel dispensers 38 disclosed herein, based on that configured in the printhead disclosed in WO 2017 / 187153, is particularly suited for this method, as it provides digitally controllable dye flow in both transport and cross-web directions, highly accurate deposition, high cross-web uniformity, the possibility of instantaneous color switching by digital control of the elements, and a parallel air flow that adds but guarantees penetration into the fabric without further adsorption promotion steps, in the order of 5 ms. -1 It is characterized by high droplet velocities exceeding

[0087] Referring to FIG. 5, an exemplary array of channel dispensers 38 for dispensing atomized dye droplets 42 onto pre-hydrated fibers of a textile substrate 44 is shown. Also shown is an airflow 40 directed against the dispensing tip of the fluid channel dispenser 38. The airflow 40 is oriented generally perpendicular to the length of the fluid channel dispenser 38 and generally parallel to the direction of movement of the dispensed fluid.

[0088] As mentioned above, in some embodiments of the disclosed device, the airflow 40 can deflect the fluid droplets dispensed from the flow path dispenser 38 and thus control the spread profile of the spray droplets 42 of fluid dispensed onto the textile substrate 44.

[0089] Beneficially, controlling the droplet profile and spread allows for greater resolution in dispensing of fluid and allows for in-line correction of detected inconsistencies in the textile substrate 44. The velocity of the airflow may be controlled by the processor 50.

[0090] Furthermore, directing the air flow 40 against the tip of the flow path dispenser 38 reduces the risk of dispensed fluid accumulating at the nozzle tip of the dispensing element, blocking the nozzle or reducing the homogeneity of the dispensed fluid, a problem known with printheads for dispensing other types of fluids, such as ink.

[0091] The ability to deflect the dispensed fluid with the air stream 40, and therefore control the spread area of ​​the fluid on the textile substrate 44, also allows for real-time, versatile control of the application of dye to the textile substrate in-line.

[0092] In some embodiments, the airflow 40 is periodically applied to the dispensed spray droplets 42. For example, the processor 50 may dispense the airflow at a frequency in the range of 1 to 1,000 Hz.

[0093] The periodic deflection of the spray can be used to improve averaging between adjacent nozzles, improve uniformity of dispensed fluid across an array of flow path dispensers, or to correct detected inconsistencies in the textile substrate 44 in-line.

[0094] In some embodiments, pressures in the range of 2-10 PSI, i.e., 14-69 kPa, and pressures in the range of 1-100 cubic feet per minute, i.e., 0.00047-0.047 m 3 s -1 The airflow is driven by a flow rate of

[0095] As previously mentioned, the array of fluid channel dispensers are each independently controlled by a processor. Similarly, the airflow 40 is regulated by an airflow controller (not shown), which is digitally controlled by the processor 50.

[0096] Sensors for determining one or more parameters of the fabric and detecting inconsistencies in the fabric are also in communication with the processor 50. Alternatively, the sensors are in communication with a different processor 50.

[0097] In an exemplary embodiment, the processor 50 corresponds to a microcontroller, a system on a chip, or a single board computer. The processor 50 includes a volatile memory, a non-volatile memory, and an interface. In some corresponding embodiments, the processor 50 may include multiple volatile memories, non-volatile memories, and / or interfaces. The volatile memories, non-volatile memories, and interfaces communicate with each other via a bus or other form of interconnection. The processor 50 executes computer readable instructions, such as one or more computer programs, for controlling some aspects of the system described herein. The computer readable instructions are stored in the non-volatile memory. The processor 50 is powered by a power source, which may include a battery.

[0098] [1. Dye application] [Fluid Delivery (jetting [nozzle 500um], vacuum)] 6 illustrates an exemplary processing line 100 with a first pass and a second pass. The first pass is defined by a first application of dye via a first array of channel dispensers 138, and the second pass is defined by a second application of dye via a second array of channel dispensers 139. Any number of passes and / or arrays of channel dispensers may be used, such as 3, 4, 5, 6, 8, 10, or 10 or more passes and / or arrays of channel dispensers.

[0099] In the example treatment line shown in Figure 6, the path of the textile fabric 44 is defined by a number of rollers 110. The rollers 110 define turning points for the textile fabric 44 such that the total length of the line is significantly less than the horizontal distance from inlet to outlet because the treatment line 100 is convoluted with multiple folds in the textile fabric formed by the rollers 110. To prevent transfer of aqueous dyes between the textile fabric and the rollers 110, commonly referred to as offsetting, the rollers 110 have a hydrophobic outer surface and / or coating, such as Teflon.

[0100] The processing line 100 shown in FIG. 6 includes a first array 138 and a second array 139 of channel dispensers, resulting in a two-pass process. The first array 138 of channel dispensers is followed by a first drying stage 140, and the second array 139 of channel dispensers is followed by a second drying stage 141. The first and second drying stages each include at least one of infrared (IR) heating, near infrared (NIR) heating, mechanical infrared (MIR) heating, microwave heating, ultraviolet (UV) heating, and plasma heating. The processing line 100 further includes a first vacuum chamber 145 under the textile fabric 44 under the first array 138 of channel dispensers and a second vacuum chamber 146 under the textile fabric 44 under the second array 139 of channel dispensers. The first vacuum chamber 145 is connected to a first vacuum pump 171 and the second vacuum chamber 146 is connected to a second vacuum pump 172, the first and second vacuum pumps being configured to control the airflow generated by each vacuum chamber via the processor 50.

[0101] 7 illustrates an exemplary configuration of a channel dispenser 200 in the first array 138 of channel dispensers for dispensing dye onto a textile substrate 44, plus at least one vacuum chamber 145. The direction of movement of the textile substrate 44 relative to the channel dispenser 200 and vacuum chamber 145 is indicated by arrow D. S1. The textile fabric 44 may move relative to the dosing element 138 and / or vacuum chamber 145 at a speed of up to 25 meters per minute. The textile fabric 44 may move relative to the dosing element 138 and / or vacuum chamber 145 at a speed of up to 100, 75, 50, 30, 25, 20, 15, 12, 10, 8, 5, 3, 2, or 1 meters per minute. Alternatively, the line 100 may be configured such that the textile fabric 44 moves relative to the dosing element 138 and / or vacuum chamber 145 at less than 1, 0.8, 0.5, 0.3, or 0.1 meters per minute. The speed of the textile fabric 44 may be adjusted from run to run or in real or near real time during a dye run. For example, the textile fabric 44 may move relative to the dosing element 138 and / or vacuum chamber 145 at a speed of up to 35 meters per minute. Specifically, the textile substrate 44 may be moved relative to the dosing element 138 and / or vacuum chamber 145 at a speed of approximately 25 meters per minute.

[0102] The vacuum chamber 145 is indicated by arrow D. A The dosing element array is configured to generate an airflow, indicated by a vacuum chamber at , which draws the dye droplets 42 towards the textile substrate 44. The addition of the vacuum chamber increases the volume of dispensed dye that reaches the textile substrate 44, significantly reducing overspray. In some embodiments, nearly all of the dispensed dye reaches the textile substrate 44. This reduces the need for maintenance within the array of dosing elements, as the amount of dye coating the internal members and components of the system over time is significantly reduced or eliminated. Dye build-up on and / or around the dosing tip may also be eliminated or significantly reduced.

[0103] The dosing element 200 may be approximately 500 μm in diameter. In some embodiments, the dosing element 200 may be up to 1000 μm, 800 μm, 600 μm, 500 μm, 400 μm, 200 μm, or 100 μm in diameter.

[0104] The dosing element 200 may include a tip 201 from which dye may be dispensed. The tip of the dosing element may be approximately 15 mm above the textile substrate. In some embodiments, the dosing element may be up to 30 mm, 25 mm, 20 mm, 17 mm, 15 mm, 13 mm, 10 mm, 5 mm, or 1 mm above the textile substrate.

[0105] 8 shows an array of flow dispensers comprising a first bank A of flow dispensers and a second bank B of flow dispensers. Each bank of flow dispensers is configured to provide up to 500 dosing elements per meter. Each bank of flow dispensers may include dosing elements spaced apart by about 0.5 mm to 10 mm. In some embodiments, the spacing is about 1 mm to 5 mm, or 2 mm to 3 mm. In some embodiments, each array of flow dispensers may include at least two banks of flow dispensers configured to provide dosing elements spaced apart by about 1 mm to 2 mm.

[0106] In some embodiments, each array and / or bank of flow channel dispensers may include a separate dye supply tank, and each dye supply tank may include a different color, tone, shade, surface finish, and / or function.

[0107] Alternatively, multiple arrays and / or banks of channel dispensers may share a single shared dye supply tank. Each array of channel dispensers can hold up to 200g / m 2 In some embodiments, each array of flow path dispensers may be configured to dispense up to 150 g / m 2 , 120g / m 2 , 100g / m 2 , 80g / m 2 , 60g / m 2 , or 50 g / m 2 In some embodiments, each array of flow path dispensers may be configured to dispense 0 g / m 2 From 200 g / m 2Between 5g / m 2 from 1500g / m 2 Between 10g / m 2 From 80g / m 2 The dye may be dispensed onto the textile substrate.

[0108] Alternatively or additionally, the processing line may be configured to dispense between 3 and 5 liters of dye per minute. In some embodiments, the processing line is configured to dispense between 2 and 8 liters, between 1 and 10 liters, and / or between 0 and 15 liters of dye per minute.

[0109] Each dosing element may be configured to dispense dye at a speed between 0 and 10 m / s. In some embodiments, the dosing elements may be configured to dispense dye at a speed of up to 1 m / s, 2 m / s, 5 m / s, 8 m / s, 10 m / s, 12 m / s, 15 m / s, 20 m / s, 25 m / s, and / or 30 m / s.

[0110] The flow rate of each dosing element can be accurate to within 1% of the desired flow rate, in some embodiments, the flow rates can be accurate to within 0.3%, 0.5%, 0.8%, 1%, 1.5%, 2.5%, and / or 10% of the desired flow rate.

[0111] [Double-sided (same color / two colors / coating [two functions, colors, finishes])] 8 shows an exemplary woven fabric 44 during application of dye on a first pass during a two-pass processing line. The woven fabric may have a first surface 45 and a second surface 46, where the first pass is The first pass is configured to dispense dye onto the first surface 46 and the second pass is configured to dispense dye onto the second surface 46. The direction of movement of the textile substrate 44 relative to the channel dispensers 200, 201, 202, 203 and the vacuum chamber 145 is indicated by arrows D. SThe dye droplets 42 are sprayed toward a first surface 45 of a textile substrate 44. The vacuum chamber 145 can be configured to create an airflow such that the dye droplets 42 penetrate less than 100% of their way through the textile substrate, as indicated by dashed line 150.

[0112] In some embodiments, the vacuum chamber 145 may be configured to generate an airflow such that the dye droplets 42 penetrate up to 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, or 55% of the path through the textile fabric. The vacuum chamber 145 may be configured to generate an airflow such that the dye droplets 42 penetrate at least 50% of the path through the textile fabric. Preferably, the vacuum chamber 145 may be configured to generate an airflow such that the dye droplets 42 penetrate between 50% and 95% of the path through the textile fabric. Most preferably, the vacuum chamber 145 may be configured to generate an airflow such that the dye droplets 42 penetrate between 55% and 75% of the path through the textile fabric.

[0113] It is intended that the dye will penetrate 100% of the way through the fabric, thereby preventing it from emerging from the second surface 46 of the fabric substrate 44 and entering the vacuum chamber. Additionally, it may also prevent the second surface 46 from receiving dye that may be transferred to the downstream roller 110, thus preventing "offsetting."

[0114] The strength of the airflow generated by the vacuum chamber is controlled to optimize the penetration of the dye into various textile fabrics. Depending on the textile and dye, the optimization of the penetration can be appropriately set so that the dye does not completely penetrate the textile fabric.

[0115] 6, during the second pass, dye may be applied to the second surface 46 of the textile substrate 44. The dye droplets 42 may be sprayed toward the second surface 46 of the textile substrate 44, and the vacuum chamber 146 may be configured to create an airflow such that the dye droplets 42 penetrate less than 100% of the way through the textile substrate.

[0116] In some embodiments, the vacuum chamber 146 may be configured to generate an airflow such that the dye droplets 42 penetrate up to 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, or 55% of the path through the textile fabric. The vacuum chamber 146 may be configured to generate an airflow such that the dye droplets 42 penetrate at least 50% of the path through the textile fabric. Preferably, the vacuum chamber 146 may be configured to generate an airflow such that the dye droplets 42 penetrate between 50% and 95% of the path through the textile fabric. Most preferably, the vacuum chamber 146 may be configured to generate an airflow such that the dye droplets 42 penetrate between 55% and 75% of the path through the textile fabric.

[0117] Thus, the two pass process allows for the dye to be applied throughout the entire thickness of the textile fabric. The time between the first and second pass may allow for the dye to dry and / or set so that no offset occurs between the textile fabric and the roller 110 (if the dye molecules diffuse into the textile fabric).

[0118] Further, it should be understood that the concentration of dye applied to a given depth within the woven fabric thickness during the first pass will be less than the concentration of dye applied to the first surface 45. However, during the second pass, the dye may again penetrate at least 50% of the way through the entire thickness of the woven fabric, thus recoating at least a portion of the woven fabric thickness. The penetration depth of the dye during the first and second passes may be optimized such that the portion of the woven fabric that receives dye during both the first and second passes is also optimized. In some embodiments, the woven fabric may be coated with at least 50% of the dye. None of the ground receives dye during both the first and second passes.

[0119] In some embodiments, the dye applied during each pass may vary. The amount of dye, and therefore the shade, color, finish, and / or functionality, may vary between each pass. The first amount of dye applied during the first pass may have a first color, a first finish, and a first function. The second amount of dye applied during the second pass may have at least one of a second color, a second finish, and / or a second function. Any number of passes may be used and any number and / or combination of colors, finishes, and functions may be applied. The first and second amounts of applied dye may be the same and / or different amounts. Applying different amounts of dye during the first and second passes may be used to control, modify, and / or adjust the shade of the dyed textile fabric on the first 45 and second 46 surfaces.

[0120] For example, the color, tone, and / or shade of the dye may or may not vary among the array of dosing elements. The finish of the dye dispensed in each array of dosing elements may be, for example, at least one of matte, gloss, shiny, and / or patterned. Alternatively or additionally, the dye dispensed in each array of dosing elements may provide, for example, at least one of water resistance, flame retardancy, and / or a fluorescent label.

[0121] In some embodiments, each array of dosing elements may dispense the same dye having the same color, finish, and function.

[0122] [Shape / Width] In some embodiments, the textile substrate may be fed onto the processing line multiple times, allowing any number of different colors, finishes, and features to be applied to the textile substrate. Each flow-through metering element may be dosed differently during each subsequent processing of the textile substrate, allowing a combination of colors, patterns, finishes, shades, and / or images to be transferred onto the textile substrate.

[0123] In some embodiments, the amount of dye dispensed from a single array of dosing elements may vary along the width and / or length of the textile fabric. For example, some dosing elements in an array may be adjusted by a processor to dispense different amounts of dye compared to adjacent dosing elements. In some embodiments, multiple dosing elements may be configured to stop dispensing entirely, either temporarily or permanently. This may be used to produce textiles with patterns such as horizontal and / or vertical stripes.

[0124] Alternatively or additionally, each dispenser may be configured to be capable of being changed between an off position and an on position so that shapes, patterns, distinct lengths, and / or varying widths of dye may be applied to the textile fabric while continuously feeding the textile fabric onto the processing line.

[0125] In some embodiments, the array of flow channel dispensers is about 1.8 m wide. In some embodiments, the array of flow channel dispensers can be up to 0.1 m, 0.3 m, 0.5 m, 1 m, 1.5, 1.8 m, 2 m, 2.5 m, 3 m, 5 m, 10 m, or more than 10 m wide. Each array of flow channel dispensers can be configured such that the width of a dosing element that dispenses dye, in use, can be up to 100%, 80%, 60%, 50%, 30%, 20%, 10%, or less than 10% of the overall width of the array of flow channel dispensers.

[0126] In some embodiments, the processing lines are shaped and / or patterned to conform to the shape and / or pattern dispensed by the first array of flow path dispensing elements, and the shape and / or pattern dispensed by the second array of flow path dispensing elements. 6 and 8, a first T-shirt shape may be dispensed onto a first surface 45 of the textile substrate by a first array of dispensing elements 138. A second array of dispensing elements 139 may then be configured to dispense dye to a second T-shirt shape onto a second surface 46 of the textile substrate such that the second T-shirt shape is dispensed in approximately the same area as the first T-shirt shape, but on a different surface of the textile substrate.

[0127] [In-line drying and fixing (radiation / energy [IR / nIR / UV / plasma])] FIG. 9 shows an example of a drying stage of a processing line. The drying stage 140 comprises a drying unit 142 arranged above the textile fabric 44 and configured to emit energy as electromagnetic waves 143. The drying unit may emit between 20 kW and 200 kW of energy. For example, the drying unit is configured to transfer about 50 kW of energy to the textile fabric. Thus, a 90-150 kW drying unit may be used. The energy emission may be in the form of infrared (IR), near infrared (NIR), mid infrared (MIR), microwave, and / or ultraviolet (UV). Alternatively or additionally, plasma heating may also be used.

[0128] The drying unit 142 further includes an airflow configured to remove steam and / or humidity, if any, from the vicinity of the textile fabric 44. The airflow may be configured to remove up to 5 liters of water vapor per minute from the vicinity of the textile fabric. In some embodiments, the airflow is configured to remove up to 4, 3, 2, 1.5, 1 0.5, and / or 0 liters of water vapor per minute from the vicinity of the textile fabric. In some embodiments, the removed water vapor is disposed of as waste. In some embodiments, waste water and / or heat is captured and recycled or reused.

[0129] The textile fabric may enter the drying stage with a moisture content of about 25%. In some embodiments, the textile fabric leaves the drying stage with a moisture content of between 0% and 5%. In some embodiments, the textile fabric leaves the drying stage with a moisture content between 2% and 10%.

[0130] The drying stage comprises a reflector 147 disposed below the textile substrate and configured to optimize the amount of emitted energy transferred to the textile substrate 44 . The drying stage includes at least one temperature sensor 160 configured to measure the temperature of the textile fabric 44 as it leaves the drying stage. The textile fabric enters the drying stage at approximately room temperature, which may be between 5°C and 45°C, but more preferably between 10°C and 35°C, and most preferably between 15°C and 30°C. During the drying stage, the textile fabric may increase in temperature by between 5°C and 60°C, more specifically between 20°C and 40°C. For example, the textile fabric may enter the drying stage at about 25°C and leave the drying stage at about 60°C.

[0131] [Adhesion when applied] Figure 10 shows an exemplary textile fabric 44 during a drying stage 140. The drying stage first reduces the moisture content 149 of the dye droplets 142. As shown in Figure 11, the removal of moisture content from the textile fabric and dye droplets prevents a significant temperature increase due to the latent heat of evaporation required to evaporate the water. When the moisture content of the textile fabric drops below about 10%, fixation of the dye to / within the textile fabric begins to occur.

[0132] In some embodiments, the drying stage may be configured to at least partially fix the dye to the textile substrate. The energy provided by the drying unit 142 may be sufficient to at least partially fix the dye to the textile substrate, such that at least some of the dye may have sufficient energy to react with or diffuse into the textile fibers. The dye-containing textile fabric may be configured to locally activate a portion of the dye, which may initiate a chemical or physical fixing process. Thus, in some embodiments, infrared (IR) radiation may be used to initiate the fixing process between the dye and the textile fabric. More specifically, in some embodiments, infrared (IR) radiation may be used to reduce the moisture content of the textile fabric containing the dye, concomitantly effecting the fixing process between the dye and the textile fabric.

[0133] In some embodiments, the energy emitted by the drying unit may be controlled, regulated, and / or optimized. Furthermore, in some embodiments, the energy provided by the drying unit may be non-uniform along the length of the drying unit. The amount, type, and / or wavelength of the energy may vary along the length of the drying unit. Doing so may allow for optimizing the absorption, removal or water of the dye, and / or the fixing process between the dye and the textile fabric. For example, the drying unit may initially radiate mid-infrared wavelengths to the textile fabric to efficiently remove the water content from the textile fabric and dye. The drying unit may then change further along the process to radiating near-infrared (NIR) to efficiently initiate the fixing process between the dye and the textile fabric, such as polyester or nylon.

[0134] Initiating, and in some embodiments completing, the fixing process during the drying stage can be used to completely eliminate the need for a separate fixing stage at the end of the processing line. This can significantly reduce the time it takes to process a textile fabric, as incorporating fixing into the drying stage using electromagnetic waves such as IR can take approximately 0.5 to 10 seconds.

[0135] During the drying stage, the fixation of the dye to the textile fabric is completed, resulting in the textile fabric reaching a temperature of up to 200° C. or more. Alternatively or additionally, the time that the textile fabric spends in the drying stage to allow fixation to be completed can be increased to up to 10 seconds.

[0136] [Temperature (150℃~240℃)] FIG. 11 shows an example of how the moisture content of a dye on a textile fabric varies with time as a change in temperature is applied. Line A shows how the moisture content decreases with time during the drying process. Line B shows how the temperature of the textile fabric varies with time during the drying process. Line C shows the point in time when fixation of the dye to the textile fabric begins to occur. The nearly horizontal portion of line B, i.e., the smallest change in the textile fabric temperature with time, occurs as a result of the energy required to overcome the latent heat of evaporation of the water in the textile fabric and / or the dye.

[0137] [Chemistry] In some embodiments, the processing line may dispense dyes that include less than 10, 7, 5, or 3 components. At least one of the components may be pigment and / or water. The dyes may be disperse dyes that are physically trapped within hydrophobic fibers, such as polyester. The dyes may be fixed to the fibers using a binder, which is thermally fused to the fibers. The dyes may be fixed to the fibers using a chemical reaction, such as an acid-base electrostatic interaction. The dyes may be fixed via a precipitation reaction involving two liquid components. All, or nearly all, of the dye dispensed ends up on the textile substrate, thus requiring simplified chemistry. This is in contrast to current state of the art systems that use multiple washing steps to remove certain components of the dye from the dyed fabric. The simplified chemistry may result in less expensive dyes and significantly lower environmental impact due to fewer additives required. Additionally, the dyes may have an average dye particle size (D50) between 0.1 μm and 20 μm, 0.5 μm and 10 μm, or 1 μm and 5 μm.

[0138] The dyes of the present invention may be used with any woven fabric, including, for example, polyester, cotton, nylon, polycotton, elastane, and viscose. For example, it may be used with any dispensing means including spraying and ink jet printing.

[0139] In some embodiments, the dye is continuously recirculated in the dye supply tank. Continuously recirculating the dye in the dye supply tank keeps the dye particles suspended, thus requiring less auxiliary agents such as leveling agents. In some embodiments, the dye may be in a soft-settled suspension, i.e., a dispersion that can be resuspended in a fluid stream.

[0140] [2. Completion of adhesion] 12 shows an example of the fixing stage 20 within some embodiments of the processing line 100. The woven fabric 44 enters a fixing enclosure 33 that includes a number of rollers 210-216 configured to define a path for the woven fabric through the fixing enclosure. Any number of rollers may be used within the fixing enclosure. Upon exiting the fixing enclosure, the woven fabric 44 is wound onto an unwind module 36.

[0141] The fixation enclosure is configured to allow the dye to further diffuse into the textile fabric and chemically react with the fabric and thermally fuse with the fabric. The fixation process may include at least one of solid-state diffusion, gas-phase sublimation, melting, chemical reaction, and precipitation. For example, the dye may undergo sublimation. In some embodiments, sublimation of the dye improves the efficiency with which the dye diffuses into the fabric. Alternatively, in some embodiments, sublimation of the dye is prevented. Preventing sublimation of the dye may be achieved by reducing the temperature of the fixation enclosure and / or reducing the time spent by the fabric in the fixation enclosure.

[0142] Control (Time) The rollers 210-216 are configured to move relative to one another to lengthen or shorten the path length the fabric must take within the fixation enclosure 33. For example, rollers 211, 213, and 215 move downward toward rollers 210, 212, 214, and 216, and / or rollers 212 and 214 move upward toward rollers 211, 213, and 215. Doing so shortens the path length of the woven fabric 44 and therefore the time the woven fabric spends within the fixation enclosure 33.

[0143] The woven fabric 44 may spend approximately 60 seconds within the bonding enclosure 33. In some embodiments, the woven fabric may spend up to 60, 90, 120, or 180 seconds within the bonding enclosure. In some embodiments, the woven fabric may spend less than 60, 50, 40, 30, 20, 10, 8, 6, 5, 3, or 1 seconds within the bonding enclosure. Reducing the time spent within the bonding enclosure may prevent the woven fabric 44, such as polyester, from shrinking and ensure a good hand or "hand".

[0144] The textile web may travel along the processing line at approximately 25 meters per minute. Thus, the textile web may travel through the fastening enclosure at approximately 25 meters per minute.

[0145] [Mechanical control (heat setting / stenter)] The bulk bonding enclosure 33 may be configured to be between 100° C. and 300° C. In some embodiments, the bonding enclosure is configured to be between 140° C. and 220° C., and in some embodiments, the bonding enclosure is configured to be between 180° C. and 200° C. The temperature of the bonding enclosure 33 may be controlled and / or regulated such that any temperature between room temperature and 300° C. is achievable.

[0146] In some embodiments, the adhesion enclosure 33 may be filled with an inert gas, which may be nitrogen and / or steam. In some embodiments, the bonding stage further comprises a mechanical constraint, such as a stenter, configured to prevent the textile fabric from shrinking during the bonding process. The mechanical constraint may grip and / or pull the textile fabric for the duration of the bonding process to prevent the textile fabric from shrinking.

[0147] [IR] In some embodiments, the bonding enclosure may include infrared (IR) or near infrared (NIR) electromagnetic waves. This may significantly reduce the time taken during bonding enclosure. For example, the time spent by the textile fabric in the bonding chamber may be less than 20 seconds. In some embodiments, the time spent by the textile fabric in the bonding chamber may be less than 15, 10, 8, 6, 5, 4, 3, 2, or 1 second.

[0148] In some embodiments, there is no fixation chamber 33 at all. In such embodiments, the fixation process may take place entirely within the drying stage.

[0149] [3. Digital dyeing] 13 illustrates a flow diagram of an exemplary method implemented by the processor 50. Input data 300 is input into the processor 50. The processor comprises an intelligence module 320 configured to determine at least one processor setting 340 based on the input data 300. The processor 50 then generates an output 360 based on the process setting 340.

[0150] [Intelligence (Fluid Application / IR / Fluid Adhesion)] The input data 300 may include at least one of: woven fabric basis weight (GSM), woven fabric moisture content (%), woven fabric thickness (mm), woven fabric air permeability (H / m), woven fabric temperature before, during, and / or after the drying step (°C), woven fabric color before, during, and / or after the dyeing step (HU), woven fabric color before, during, and / or after the fixing step (HU), woven fabric temperature before, during, and / or after the fixing step (°C), woven fabric speed throughout the processing line (m / s), dye type, dye concentration (mol), and flow rate. In some embodiments, the input data may be calculated or measured on the processing line.

[0151] The intelligence module 320 may include a database 380 configured to store data. The database may store data configured to match the input data 300 with at least one of the processor settings 340 and the processor output 360. For example, a given input or combination of inputs may require a particular combination of processor settings to generate a desired and / or optimal output. This combination of data may be stored in the database such that the optimal output may be achieved quickly and efficiently. Doing so reduces the amount of suboptimal woven fabric and therefore the time and cost to manufacture a finished woven fabric.

[0152] [control] The processor settings 340 may include at least one of the flow rate of dispensed dye (l / min), the amount of energy delivered during the dyeing and / or fixing stages (J), and the temperature in the fixing enclosure (° C.), each of which may be adjustable by the processor during use.

[0153] [measurement] 14 illustrates an example processing line 100 that includes at least one sensor. The at least one sensor may be configured to determine input data 300. The input data may include a dye The dye concentration may be determined before the color step, during the dye step, or after the dye step. The processing line includes a first sensor 400 configured to determine the basis weight of the textile fabric, a second sensor 404 configured to determine the moisture content of the textile fabric, a third sensor 408 configured to determine the flow rate of dye being dispensed by the first array of channel dispensers 138, a fourth sensor 412 configured to determine the temperature of the textile fabric after the first drying stage 140, a fifth sensor 416 configured to determine the color of the textile fabric after the first drying stage 140, and a fifth sensor 418 configured to determine the color of the textile fabric after the second array of channel dispensers 139. a sixth sensor 420 configured to determine the flow rate of the dye being applied to the textile fabric after the second drying stage 141; a seventh sensor 424 configured to determine the temperature of the textile fabric after the second drying stage 141; an eighth sensor 428 configured to determine the color of the textile fabric after the second drying stage 141; a ninth sensor 432 configured to determine the flow rate of the first vacuum chamber 145; a tenth sensor 436 configured to determine the flow rate of the second vacuum chamber 146; and an eleventh sensor 440 configured to determine the color of the textile fabric after the fixing stage 20.

[0154] 15A shows a processing line 100 in which first and second dyes are applied to a substantially horizontal surface of a textile fabric. The processing line includes a first dyeing and drying / fixing stage 180 configured to dye a first substantially horizontal surface 185 of the textile fabric, and a second dyeing and drying / fixing stage 181 configured to dye a second substantially horizontal surface 186 of the textile fabric. Between the first dyeing and drying / fixing stage 180 and the second dyeing and drying / fixing stage 181, the textile fabric is inverted using a plurality of rollers 110.

[0155] FIG. 15B shows an exemplary processing line in which dye is applied to a substantially vertical surface of a woven fabric. The processing line comprises a first dyeing and drying / fixing stage 180 configured to dye a first surface 187 of the woven fabric, and a second dyeing and drying / fixing stage 181 configured to dye a second surface 188 of the woven fabric. The first stage 180 and the second stage 181 are provided on the same span of the woven fabric, i.e. the roller 110 is provided without changing the fabric direction between the first stage 180 and the second stage 181. The roller 110 is configured such that the woven fabric is moved at approximately 45° to the horizontal, so that neither the first stage 180 nor the second stage 181 are too close to the vertical. This is because it is easier for the dye to be at least partially gravity fed. The illustrated example shows an offset of the first stage 180 and the second stage 181, but it is also possible to align them so that the fabric is dyed from both ends simultaneously.

[0156] 15C shows a processing line 110 including a drum 111 configured to determine the path of the textile fabric 44. The use of a drum 111 instead of a roller 110 increases the contact area with the fabric and reduces the total number of moving components on the processing line.

[0157] [Switching (Fluid)] FIG. 16 illustrates a dye supply, circulation, and drainage system for a dosing element of the present invention. The flow path dispenser 200 is in fluid communication with a dye holding tank 500 configured to contain liquid dye. Initially, the dye holding tank 500 may be empty of dye. The holding tank 500 is in fluid communication with the supply tank 34 via a supply inlet 510 and a return outlet 520. The supply inlet 510 includes an inlet pump 512 operably connected to a holding tank level sensor 514 via a wire 516. The holding tank level sensor 514 is configured to monitor the level, and therefore the volume, of the dye in the holding tank 500. The inlet pump 512 is turned on to pump the dye from the supply tank 34 to the holding tank 500. The pump 512 is then turned off when the level in the holding tank 500 reaches a predetermined level. The system is then ready to use.

[0158] The dye level and / or volume in the holding tank is below the desired level and / or volume. When it drops, the level sensor 514 issues an alarm that is configured to turn on the pump 512 and pump dye from the supply tank 34 to the holding tank 500 via the supply inlet 510. When the dye level and / or volume in the holding tank reaches a predetermined level and / or volume, the level sensor 514 sends an alarm to the pump 512 to turn off, thus preventing over-dispensing of dye. As dye is being dispensed from the dosing element 200, this process operates continuously so that the dye level and / or volume in the holding tank remains approximately constant.

[0159] The holding tank further comprises a return outlet 520 that includes an outlet pump 522 configured to pump dye from the dye holding tank 500 to the supply tank 34 . The supply inlet 510 and inlet pump 512 can be turned off / closed. The return outlet 520 and outlet pump 522 are then configured to drain substantially all of the dye from the holding tank 500. This allows the supply tank 500 and dosing element 200 to be cleaned, maintained, and / or the dye color, surface finish, functionality, and / or any other characteristics to be changed. For example, the supply tank 34 can be replaced with a new supply tank.

[0160] In some embodiments, the supply inlet 510 and the return outlet 520 operate simultaneously. This allows for continuous recirculation of dye from the supply tank 34 to the holding tank 500 and back again. When the dosing element is in use, the supply inlet 510 may have a higher flow rate than the return outlet 520 so that the level and / or volume of dye in the holding tank remains approximately constant. The flow rate at the return outlet 520 may be about 50 ml / min. Alternatively or additionally, the flow rate at the return outlet 520 may be about 10% of the flow rate of the supply inlet 510. Recirculating the dye using the supply inlet 510 and the return outlet 520 may be used to keep particles suspended in the dye, thus reducing the number of additives or agents required in the dye.

[0161] In some embodiments, the level and / or volume of dye in the holding tank 500 may fluctuate. In some embodiments, the level sensor is configured to alert the inlet pump 516 when the level of dye in the holding tank 500 reaches a level below a predetermined threshold. The predetermined threshold level may be level with the top of the dosing element 200.

[0162] In some embodiments, the holding tank 500 comprises a vacuum inlet 530. The vacuum inlet 530 is connected to a vacuum pump 535 configured to create a negative pressure in the holding tank 500. The negative pressure in the holding tank can be configured to prevent dye from being dispensed from the dosing element 200. For example, as the holding tank 500 fills with dye, the dosing element 200 also begins to fill with dye. At a certain point, when the holding tank is partially filled, the dosing element 200 becomes full. However, careful control of the negative pressure created by the vacuum inlet 530 in the holding tank 500 can prevent dye from dripping and / or dispensing from the dosing element, thus allowing the holding tank 500 to fill to a desired liquid level.

[0163] In some embodiments, once the holding tank 500 and / or the dosing element 200 contain a desired amount of dye, the negative pressure in the holding tank may be reduced so that the dosing element dispenses a predetermined amount of dye. This may be used to ensure that the system is operating effectively and efficiently, in addition to verifying that the correct dye is present in the system.

[0164] In some embodiments, the vacuum inlet 530 is configured to create a negative pressure within the holding tank 500 to prevent dye from entering the dosing element 200 completely. 17 illustrates an exemplary dye supply, circulation, and drainage system for a dosing element that includes a holding tank 500. The holding tank 500 is connected to the holding tank 51 via a conduit 555. 0. The vacuum inlet 530 and the supply inlet 514 may be connected to the header tank 550.

[0165] The vacuum inlet 530 is in fluid communication with a drip tank 560 configured to collect any dye that is unintentionally drawn into the vacuum inlet 530. The drip tank 560 is configured to prevent the dye from entering the vacuum pump 535.

[0166] At least one of the feed inlet 510, feed pump 512, holding tank 500, conduit 555, header tank 550, return outlet 520, and outlet pump 522 are coated with a hydrophobic material, such as Teflon. The coating is applied to any surface intended to be in fluid contact with the dye.

[0167] The changeover method to be arranged may be varied according to the requirements of the particular dye and the fabric to be dyed. However, the process generally involves the initiation of switching off the feed pump 512 and the outlet pump 522 to remove all remaining dye from the header tank 550. A wash cycle may then be initiated, where water and detergent are introduced into the header tank 550 and then flushed from the header tank 550. Depending on the nature of the dye, specifically the dye color, one or more wash cycles may be provided. The dosage of detergent within each wash cycle may be changed to a maximum detergent given in the first wash cycle and a minimum detergent given in the last wash cycle. In fact, the last wash cycle may be accomplished without any detergent at all. Once the last wash cycle is completed, the header tank 550 may be refilled with new dye. In connection with the selection of the number of wash cycles, the colors of the two dyes before and after the changeover may be taken into account. For example, changing from a yellow dye to black may be achievable in a single wash cycle, whereas changing from a black dye to yellow may require three wash cycles.

Claims

1. Determining one or more parameters of a textile fabric (10); determining, by a processor (50), at least one dose setting for an array of flow path dispensers (38) of a processing line (32), wherein determining the at least one dose setting is based on the one or more parameters (12); dispensing dye onto the textile according to the at least one dose setting (14) by the array of channel dispensers; imparting energy to the fabric to fix the dye within the fabric; Including, A method for digitally controlled application and fixation of dyes to textiles on a processing line.

2. The one or more parameters include parameters of the textile to be dyed, The method of claim 1.

3. The one or more parameters include parameters of a dyed textile. The method according to claim 1 or 2.

4. The one or more parameters are determined in real time or near real time. The method according to any one of claims 1 to 3.

5. the one or more parameters are determined continuously; The method according to any one of claims 1 to 4.

6. Each of the fluid channel dispensers is independently controlled; The method according to any one of claims 1 to 5.

7. the amount of dye to be dispensed onto the fabric is equal to or less than the saturated absorption capacity of the fabric; the saturated absorption capacity is determined based at least in part on the one or more parameters. The method of claim 1.

8. the amount of dye to be dispensed onto the fabric exceeds the saturation absorption capacity of the fabric, the saturated absorption capacity is determined based at least in part on the one or more parameters. The method of claim 1.

9. The dose setting is determined based at least in part on the target shade. The method according to any one of claims 1 to 8.

10. and wherein the dispensing further includes providing feedback in response to detecting, by the at least one sensor, an area of ​​the textile surface including a color mismatch to correct the detected mismatch. The method according to any one of claims 1 to 9.

11. correcting the detected misalignment includes controlling an air flow (40) by the processor to deflect the dispensed dye to compensate for the primed area of ​​the textile surface (44). The method of claim 10.

12. The array of channel dispensers achieves a substantially uniform application of dye to the fabric. The dispensing tip of the flow channel dispenser is configured to be in close proximity to the textile substrate. The method according to any one of claims 1 to 11.

13. The flow channel dispenser is configured such that the dispensing tip of the flow channel dispenser is at a distance of between 5 mm and 50 mm from the fabric surface. The method according to any one of claims 1 to 12.

14. the array of channel dispensers comprises two sub-arrays of channel dispensers which dispense dye onto opposing surfaces of the fabric; The method according to any one of claims 1 to 13.

15. detecting misalignment within the array of fluid dispensers; controlling, by said processor, an airflow directed at at least one or more of said flow path dispensers and / or at the dispensed dye to adjust a flow rate or trajectory of the dispensed dye to compensate for the detected mismatch. Further comprising: The method according to any one of claims 1 to 14.

16. detecting misalignment within the array of fluid dispensers; completely pausing said processing line by said processor; Further comprising: The method according to any one of claims 1 to 15.

17. the processor independently controls each of the fluid channel dispensers; The method according to any one of claims 1 to 16.

18. The flow channel dispensing tip is an ultrasonic atomizer nozzle; The method according to any one of claims 1 to 17.

19. the fluid applicator is an inkjet printhead; 19. The method according to any one of claims 1 to 18.

20. the fluid applicator is a spray system; 20. The method according to any one of claims 1 to 19.

21. a flow rate of the dispensed dye is controlled by a processor using at least one of pressure, ultrasonic energy, and positive displacement pumping; 21. The method according to any one of claims 1 to 20.

22. and dispensing dye to at least one discrete location on the fabric by said array of channel dispensers.

22. The method according to any one of claims 1 to 21.

23. determining, by the processor, an optimal or near-optimal layout of discrete locations configured to maximize a surface area of ​​the textile to be dyed; the layout includes at least one distinct location of a textile to be dyed; 23. The method of claim 22.

24. The processor detects a small gap between the dyed and undyed fabric locations. determining at least one continuous boundary, said continuous boundary surrounding said dyed fabric location; separating, by a separation module, the portion of the dyed textile enclosed within the boundary; Further comprising:

24. The method of claim 22 or 23.

25. determining, by said processor, at least one continuous boundary between locations of dyed fabric and locations of undyed fabric; Separating, by a separation module, a portion of the fabric that includes the entirety of the at least one continuous boundary. Further comprising:

25. The method of any one of claims 22 to 24.

26. the separated portion including the continuous boundary also includes a strip of fabric surrounding the boundary; the strip is of a predetermined width; 26. The method of claim 24 or 25.

27. detecting inconsistencies in the fabric; controlling, by the processor, at least one of a jetting frequency of one or more of the flow path dispensers and an airflow directed at the dispensed dye to adjust the flow rate or a flow trajectory of the dispensed dye to compensate for the detected mismatch. Further comprising:

27. The method according to any one of claims 1 to 26.

28. Determining the one or more parameters receiving a data input including the one or more parameters; Detecting said one or more parameters using one or more sensors. at least one of 28. The method according to any one of claims 1 to 27.

29. the one or more parameters include at least one of basis weight, speed, dye concentration, fabric thickness, diameter, fabric batch code, absorbency, moisture content, color, shade, pantone, and reflectance; 29. The method according to any one of claims 1 to 28.

30. The dye dispensed from the channel dispenser is －１ In the form of spray droplets with a velocity exceeding 30. The method according to any one of claims 1 to 29.

31. and fixing the dispensed dye onto the textile.

31. The method according to any one of claims 1 to 30.

32. The fixing is carried out by application of steam at a temperature in the range of 150° C. to 250° C.; 20. The method of claim 17.

33. Fixing is effected by application of dry heat, 20. The method of claim 17.

34. the bonding is effected by application of radiation including at least one of infrared, microwave, and radio frequency radiation; 20. The method of claim 17.

35. An apparatus (29) configured to carry out the method according to any one of claims 1 to 34, comprising: a processing line (32) for conveying the textile material; A processor (50); an array of flow path dispensers, each flow path dispenser (38) independently controlled by said processor and configured to dispense dye onto said surface of a transported textile (44); Equipped with Device.

36. further comprising sensing means for detecting one or more parameters of the conveyed fabric and / or one or more inconsistencies; 36. The apparatus of claim 35.

37. Further comprising a fixing means for fixing the dispensed dye onto the conveyed textile.

37. Apparatus according to claim 35 or 36.

38. a textile unwinding module (30) located at the beginning of the processing line; a fabric unwinding module (36) at the end of the processing line; Further comprising: Apparatus according to any one of claims 35 to 37.

39. An air flow is used to direct the liquid droplets into the internal structure of the textile fabric; 35. The method according to any one of claims 1 to 34.

40. The surface tension of the liquid dye is controlled to affect fluid spreading after application to the textile substrate; 35. The method according to any one of claims 1 to 34.

41. Application of infrared energy for drying is used to control migration of liquid dyes within the fabric.

35. The method according to any one of claims 1 to 34.

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