Rotating Roller Mist Dyeing for Uniform Low-Water Brassieres
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Solution Overview
Problem
Conventional garment dyeing machines require a large quantity of water, making them environmentally unfriendly and limiting their use in areas with scarce water supply, particularly for dyeing garments like lingerie and brassieres.
Innovation Solution
A garment dyeing machine with a cylindrical container and rotating roller system that uses pressurized dye solution and air to atomize dye into nano-scale particles, reducing water usage by minimizing the fabric to dye solution ratio and incorporating a heating tank for temperature control, along with a UV light for treatment and a transparent viewing window for customer engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional garment dyeing machines use large quantity of water for dyeing garments, then the dyeing process can be completed, but the water consumption becomes excessive and environmentally unfriendly
Solution Approach 1:
The patent employs a spray system that utilizes pressurized air to atomize dye solution into fine droplets. The air nozzle delivers pressurized air that breaks the dye solution into nano-scale particles, creating a mist that evenly coats the garment. This pneumatic-hydraulic approach replaces conventional water immersion methods, dramatically reducing water consumption from a 1:4 fabric-to-dye-solution ratio to a 1:1 ratio while maintaining effective dyeing performance
Solution Approach 2:
The invention changes the physical state and delivery method of the dye solution by transforming it from a liquid bath into an atomized spray mist through pressurization. By adjusting parameters such as air pressure, spray angle, and droplet size distribution, the system achieves uniform dye penetration with minimal water usage, resolving the contradiction between adequate dyeing and water conservation
2Quantity of substance
If spray drying is used to reduce water consumption, then water usage decreases, but the dyeing uniformity may be compromised
Solution Approach 1:
The spray system divides the dye solution into numerous fine droplets of varying sizes, creating a segmented distribution pattern. This segmentation allows the dye to penetrate different areas of the garment more uniformly - finer droplets reach deeper into fabric pores while larger droplets provide surface coverage. The segmented approach ensures even dye distribution without requiring excessive water, maintaining dyeing uniformity while reducing water consumption
Solution Approach 2:
The invention transitions from two-dimensional surface spraying to three-dimensional mist penetration by atomizing the dye solution into airborne droplets that can penetrate through and around the garment structure. This dimensional change allows dye to reach internal fabric areas that conventional surface spraying cannot access, ensuring uniform dyeing throughout the entire garment while using minimal water
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 machine achieves efficient and even dyeing with significantly less water, reducing the fabric to dye solution ratio from 1:4 to 1:1, and lowers energy consumption by maintaining controlled temperature and humidity levels, while providing an environmentally friendly dyeing process.
Implementation Method 1
a motor activates a pressurizer to increase the pressure of the dye solution to around 15 kPa before being delivered to the nozzles for subsequent spraying onto the roller in the cavity of the container. Air is imparted onto the dye sprayed out from the nozzles to atomize the dye into nano-scale particles
Implementation Method 2
A heating tank is provided below the container for heating up the water in the container and the container itself. By way of such an arrangement, the temperature within the container may be kept between 30°C and 100°C
Implementation Method 3
an ultra-violet (UV) light is provided at an upper region in the interior cavity of the container for treatment of the pieces of garment (e.g. brassieres) dyed in the machine
Data Source
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AI summary
A garment dyeing machine (10) is disclosed as including a container (12), a roller (22) to which brassieres are releasably attachable, the roller (22) being within the container (12) and rotatable relative to the container (12) about an axis of rotation (R-R), and two nozzles (24) for spraying a dye solution onto the roller (22).