Tufted Carpet Dyeing Nozzle Layout for Gradation Color Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional continuous dyeing method for tufted carpets is limited in its ability to produce patterns with gradational changes and mixtures of colors, making it unsuitable for expressing complex designs at high production speeds and low costs.
Innovation Solution
The method involves using two independent dyeing liquid supply routes with nozzles that can be alternately aligned and controlled to discharge different colored dyes, allowing for simultaneous application and mixing of dye liquids on a tufted carpet during the dyeing process, enabling the creation of various patterns by gradation and color mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the conventional continuous dyeing method uses a single dyeing liquid supply route with nozzles switched between different colors, then the processing speed is high and production cost is low, but the ability to express patterns with gradation and color mixing is poor
Solution Approach 1:
The single dyeing liquid supply route is segmented into two independent dyeing liquid supply routes (Route A and Route B), each capable of supplying different colored dyes simultaneously. This segmentation allows for independent control of each route, enabling complex color patterns and gradations while maintaining the continuous high-speed processing capability of the original system.
Solution Approach 2:
The system transitions from temporal switching of colors (one route switching between colors over time) to spatial distribution of colors (multiple routes operating simultaneously at different positions). The nozzles of Route A and Route B are arranged at different locations, allowing simultaneous discharge of different colored dyes onto different portions of the carpet, creating complex color patterns in the width direction.
2Productivity
If the conventional continuous dyeing method uses a single dyeing liquid supply route, then the device complexity is low, but the processing speed and productivity are limited when producing multi-color patterns
Solution Approach 1:
Multiple dyeing liquid supply routes (Route A and Route B) are merged into a single continuous processing line, allowing simultaneous application of multiple colors in one pass. This combining approach maintains high productivity by processing the carpet continuously at high speed while achieving multi-color patterns that would otherwise require multiple sequential passes.
Solution Approach 2:
The system maintains continuous high-speed processing by operating multiple dyeing liquid supply routes simultaneously throughout the entire width of the carpet. Both Route A and Route B discharge dyes continuously during the same processing time, eliminating the need to stop or slow down for color changes, thus preserving the productivity advantage of continuous dyeing.
3Manufacturing precision
If nozzles are alternately aligned from the width direction in the dyeing liquid supply applicator, then the ability to create color patterns is improved, but the device complexity increases
Solution Approach 1:
Different nozzles are assigned to different local positions in the width direction, with nozzles from Route A and Route B alternately arranged at specific locations. Each nozzle position is optimized for its specific function (supplying specific colors to specific areas), allowing precise control over color pattern formation while maintaining a relatively simple overall structure through systematic arrangement.
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
This approach allows for efficient and cost-effective production of high-design, high-quality patterns on tufted carpets with gradational changes in hue and density, both across the width and length of the carpet, without the need for differently dyeable piles.
Implementation Method 1
the dyeing liquids different from each other in the hue or density fall on the plate, and then they contact with each other from the width direction on the plate so that they are partially mixed with each other
Data Source
AI summary
A continuous dyeing method for long original tufted carpets, including applying a dyeing liquid to the carpet while running it in the longitudinal direction with a continuous dyeing machine that includes a dyeing liquid supply applicator having an independent supply route A and supply route B, each having a plurality of nozzles capable of applying dyeing liquid to the original tufted carpet so as to uniformly flow onto the original tufted carpet through a plate. The nozzles of supply route A and supply route B are alternately aligned in the width direction, with at least one of the nozzles of each of supply routes A and B opened by the control of an opening means. The present continuous dyeing method is capable of easily dyeing an original tufted carpet a mixture of colors and/or various patterns by gradation.