Anhydrous Yarn Dyeing Using Vacuum Transfer and Laminated Ink Layers
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Solution Overview
Problem
Conventional yarn dyeing methods are inefficient, costly, and environmentally harmful due to the use of liquid dyeing processes, which generate pollutants and require multiple stages, making it difficult to achieve varied patterns and colors without increasing production costs.
Innovation Solution
An anhydrous dyeing system that laminates and prints dye ink on a transfer sheet multiple times, applies inorganic fine powder to dry the ink layers quickly, and uses a vacuum pressure in a high-temperature chamber to transfer dye to the yarn, eliminating the need for liquid dyeing and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If liquid dyeing methods are used to dye yarn, then the yarn can be dyed with various colors and patterns, but a large amount of pollutants and wastewater are generated, requiring extensive purification time and money
Solution Approach 1:
The patent changes the physical state of the dyeing medium from liquid to gas phase. By using sublimation dyeing where ice blocks directly sublime into water vapor, the system eliminates liquid dyeing processes that generate wastewater and pollutants, while still achieving comprehensive yarn penetration and color variety through vapor phase dyeing.
Solution Approach 2:
The patent utilizes phase transition of water from solid (ice) to gas (vapor) through sublimation. The ice blocks are heated to sublime into water vapor that carries dye substances, which then penetrate the yarn. This phase transition eliminates the need for liquid dyeing and subsequent washing/purification processes.
2Adaptability or versatility
If multiple dyeing tanks and winding stages are used to achieve partial dyeing and varied patterns, then color variety is improved, but device complexity and production cost increase significantly
Solution Approach 1:
The patent creates a universal dyeing chamber that can handle various dyeing requirements (different colors, patterns, partial or full dyeing) through a single integrated system. The rotating drum mechanism with multiple yarn holders and controlled vapor distribution enables one device to perform functions that previously required multiple separate tanks and winding stages.
Solution Approach 2:
The patent introduces dynamic elements including the rotating drum that can position different yarn holders, adjustable vapor flow control, and flexible timing mechanisms. These dynamic features enable a single device to adapt to various dyeing patterns and configurations without requiring multiple static dyeing tanks.
3Ease of manufacture
If conventional liquid dyeing processes are used, then yarn can be dyed, but a lot of time is required for purification processes, reducing productivity
Solution Approach 1:
By using sublimation from solid ice to gas vapor, the patent eliminates the liquid phase entirely from the dyeing process. This phase transition approach removes the need for subsequent liquid washing and purification steps, as the vapor phase dyeing leaves no liquid residue requiring removal, thereby dramatically reducing purification time.
Solution Approach 2:
The patent extracts and removes the liquid phase from the dyeing process entirely. By using only solid ice and gas vapor in the sublimation process, the system eliminates wastewater generation and the associated purification steps, extracting only the essential dyeing function while removing the harmful liquid component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables quick, efficient, and eco-friendly dyeing of yarn in desired patterns without liquid use, reducing production costs and environmental pollution by purifying pollutants.
Implementation Method 1
a vacuum-generating member which is in communication with an internal space of the dyeing jig and vacuum-evacuates the air in the internal space of the dyeing jig to thereby form a vacuum pressure inside the dyeing jig
Implementation Method 2
a heating member for heating the yarn wound on the dyeing jig, by supplying heat to the inside of the process chamber
Implementation Method 3
a transfer printer which repeatedly sprays dye ink on a surface of a transfer sheet a plurality of times to laminate and apply ink layers
Data Source
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AI summary
The present disclosure relates to an anhydrous dyeing system for dyeing yarn by using vacuum transfer. The anhydrous dyeing system for yarn, according to the present disclosure, includes: a transfer printer which repeatedly sprays dye ink on a surface of a transfer sheet a plurality of times to laminate and apply ink layers; a dyeing jig which is in a drum form having a plurality of microholes formed in an outer circumferential surface thereof to penetrate inside and outside, wherein the yarn to be dyed and the transfer sheet on which the ink layers are applied are sequentially wound on the outer circumferential surface thereof; a process chamber into which the dyeing jig is put; a heating member for heating the yarn wound on the dyeing jig, by supplying heat to the inside of the process chamber; and a vacuum-generating member which is in communication with an internal space of the dyeing jig and vacuum-evacuates the air in the internal space of the dyeing jig to thereby form a vacuum pressure inside the dyeing jig.