Engraved Roller Dyeing Machine for Leather
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Solution Overview
Problem
Current methods for dyeing leather goods are inefficient due to high water consumption, long processing times, inability to control dye distribution on both surfaces, and limitations in applying different dyes to each surface, making them costly and unsuitable for medium/small batches and surface-specific dyeing.
Innovation Solution
A machine using two engraved rollers rotating in the same direction as the leather goods, with incised surfaces to control and transfer a predetermined amount of dye onto both surfaces, allowing for surface and deep dyeing, and featuring a recirculation system to minimize water usage and prevent excess dye loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drum dyeing is used, then homogeneous dyeing is achieved, but water consumption is high and processing time is long
Solution Approach 1:
The patent introduces a transfer roller as an intermediary element that first absorbs dye from a dye bath and then transfers it to the leather good. This mediator approach allows the leather to receive dye in a controlled manner without requiring immersion in large amounts of water, thus reducing water consumption while maintaining homogeneous dye distribution.
Solution Approach 2:
The patent replaces the traditional mechanical drum rotation system with a roller-based transfer system. Instead of mechanically agitating leather in a drum, the system uses a roller to physically transfer dye onto the leather surface, reducing the need for large volumes of water and extending processing time for better dye penetration.
2Manufacturing precision
If drum dyeing is used, then homogeneous dyeing is achieved, but processing time is long
Solution Approach 1:
The transfer roller acts as a mediator that pre-saturates with dye before contact with the leather good. This allows for faster initial dye transfer compared to gradual diffusion in a drum, reducing processing time while the controlled transfer mechanism ensures homogeneous distribution is maintained.
3Loss of substance
If immersion dyeing is used, then water consumption is reduced, but control over dye amount is lost
Solution Approach 1:
The patent replaces the passive immersion process with an active mechanical transfer system. The roller's rotation speed, pressure, and contact time with the leather can be mechanically controlled to precisely regulate the amount of dye transferred, providing manufacturing precision that immersion cannot achieve while maintaining low water consumption.
Solution Approach 2:
The system allows control of dye transfer by adjusting parameters such as roller speed, pressure, and dye bath concentration. These parameter changes enable precise control over the amount of dye deposited on the leather, solving the lack of control inherent in immersion dyeing while keeping water usage low.
4Loss of substance
If immersion dyeing is used, then water consumption is reduced, but surface-specific dyeing capability is lost
Solution Approach 1:
The patent divides the dyeing process into separate stages: first, the roller absorbs dye from the bath; second, the roller transfers dye to the leather surface. This segmentation allows the process to be tailored for surface-specific dyeing by controlling roller pressure and contact time, enabling selective surface treatment while maintaining low water consumption throughout.
5Ease of operation
If conventional machines are used, then simple operation is achieved, but ability to dye both surfaces with different dyes is lost
Solution Approach 1:
The patent uses separate rollers for treating each surface of the leather good. Each roller can be independently configured with different dye baths, allowing both surfaces to receive different dyes. This segmentation maintains operational simplicity through independent control while achieving the versatility of dual-surface dyeing.
Solution Approach 2:
The roller system serves multiple functions: it can treat different surfaces with different dyes, control dye amount through parameter adjustment, and maintain low water consumption. This multi-functionality provides both versatility for different dyeing requirements and relative operational simplicity through a unified roller-based mechanism.
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 precise control of dye distribution on both surfaces, reduces water consumption, and facilitates the use of different dyes on each surface, while maintaining efficient dye transfer and easy operation, making it suitable for various leather goods processing needs.
Implementation Method 1
an incision 3 and 4, which allows a predetermined amount of dyeing liquid 5 and 6 to be held that, in pressing contact with the leather good, is transferred and is absorbed by the aforementioned leather good
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present document concerns a machine for continuous dyeing of leather items, wherein said leather items are passed through two opposite rollers (1, 2) rotating about mutually parallel rotation axes perpendicular with respect to the direction of forward motion of the leather item (P), in "synchronous" mode, i.e. with the same direction as that of forward motion of the leather item. Such a machine being characterised in that the two rollers (1,2) consist of two cylinders the outer surface of which is engraved/knurled, with the formation of pits or other cavities suitable for transferring a predetermined amount of a film (9, 10) of liquid dye product at the same time on the two surfaces of the leather aforementioned product (P1).