Automatically color mix dyeing process
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Solution Overview
Problem
Conventional textile dyeing processes are limited to cotton, require multiple steps for multi-color products, consume large quantities of water, and generate environmentally harmful dye solutions, especially when dyeing synthetic materials like polyester and nylon.
Innovation Solution
An automatic color mix dyeing process involving an automatic shaping device, a dyeing apparatus with multiple spray devices for simultaneous multi-color application, and a vapor device for color fixing, which allows for the dyeing of various materials like polyester, nylon, and cotton in a single process without using water, using a conveyor system and control devices to manage dye application and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional tank immersion dyeing is used, then cotton materials can be dyed, but polyester and nylon cannot be dyed effectively
Solution Approach 1:
The patent applies parameter changes by controlling temperature parameters to match material requirements. The system heats the tank to different temperature ranges: lower temperatures for cotton and higher temperatures for polyester and nylon, enabling effective dyeing of various materials by adjusting the thermal parameter
Solution Approach 2:
The patent implements universality by creating a multi-functional dyeing system that can handle different material types (cotton, polyester, nylon) and produce multiple colors in a single process. The automated spray system with multiple dye containers and the programmable temperature control enable the same apparatus to serve multiple material types and color combinations
2Adaptability or versatility
If multiple dyeing processes are used for multi-color products, then color variety is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple dyeing operations into a single integrated process. The automated system combines multiple dye containers, spray nozzles, temperature control, and timing mechanisms into one coordinated operation that applies multiple colors sequentially in a single batch, eliminating the need for separate dyeing processes
Solution Approach 2:
The patent replaces manual, multi-step mechanical dyeing processes with an automated control system. The microprocessor-controlled apparatus automatically manages dye selection, spray timing, temperature adjustment, and cycle sequencing, reducing operational complexity while maintaining color variety
3Reliability
If conventional dyeing processes are used, then dyeing can be performed, but large quantities of water are consumed
Solution Approach 1:
The patent uses hydraulic principles through the pump system that circulates dye solutions through the spray nozzles. This controlled fluid delivery system applies dye efficiently as a mist or spray directly onto the material, significantly reducing water consumption compared to traditional tank immersion methods where large volumes of water are required
4Reliability
If conventional dyeing processes are used, then dyeing can be performed, but harmful dye solutions are generated
Solution Approach 1:
The patent implements recovery by circulating and reusing the dye solution through the pump system. The solution is continuously recirculated through the spray system and returned to the tank for reuse, minimizing waste discharge. The system also allows for concentrated dye application reducing the volume of harmful solution that requires treatment
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
Enables efficient, water-free dyeing of multiple colors on various materials in a single process, reducing environmental impact and simplifying manufacturing by allowing for high or low temperature treatment depending on the material, and achieving cost-effective and eco-friendly dyeing.
Implementation Method 1
conveying the dyed object to a vapor device for color fixing wherein the dyed object is impregnated with vapor of 110-160° C. in the vapor device for 5-10 minutes
Implementation Method 2
conveying the shaped undyed object to a dyeing apparatus for dyeing by means of spraying wherein the dyeing apparatus includes a plurality of rows of spray devices
Data Source
AI summary
An automatic color mix dyeing process includes activating an automatic shaping device to shape an undyed object as a cylinder and tightening same; conveying the undyed object to a dyeing apparatus by means of spraying wherein the dyeing apparatus includes rows of spray devices, dye containers for containing dyes of different colors, each dye container being in fluid communication with the row of spray devices, a pump for moving the dyes in the dye containers to the rows of spray devices, and a control device for controlling the rows of spray devices to control a spray sequence, a spray time, and a spray quantity of dye; conveying the dyed object from the dyeing apparatus to a vapor device for color fixing wherein the dyed object is impregnated with hot vapor to obtain a finished object; cutting the tie ropes; and conveying, washing and drying the finished object.