Multi-section apparatus for dyeing, in an inert environment, of fabrics and yarns, with indigo and other reduction dyes
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Solution Overview
Problem
Existing dyeing systems for denim fabrics with indigo dye are complex, costly, and environmentally inefficient due to high chemical consumption, waste generation, and inconsistent dyeing results, necessitating a more economical and sustainable solution.
Innovation Solution
A multi-section dyeing apparatus operating in an inert environment with indigo and other reduction dyes, utilizing a simplified structure and a novel multiphase dyeing method with spraying and minimal dye bath volume, enabling multiple dyeing operations without intermediate oxidation phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-tank indigo dyeing systems are used, then dyeing results can be achieved, but the system complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple dyeing tanks and oxidation chambers into a single integrated tank system. The tank contains multiple dyeing zones separated by partitions, with oxidation zones positioned above the dyeing zones. This merging eliminates the need for separate tanks and intermediate transfer mechanisms, significantly reducing system complexity while maintaining reliable dyeing results through the integrated multiphase process.
Solution Approach 2:
The single tank is segmented into multiple functional zones using internal partitions. These partitions create distinct dyeing chambers and oxidation chambers within the same tank, allowing multiple dyeing operations to occur simultaneously in different zones. The segmentation enables complex multiphase dyeing processes within a simplified single-tank structure, resolving the contradiction between system complexity and dyeing reliability.
2Productivity
If conventional dyeing methods with large dye bath volumes are used, then sufficient dyeing capacity is achieved, but chemical and water consumption increase
Solution Approach 1:
The patent changes the physical parameters of the dye bath by reducing its volume while increasing the intensity of the dyeing process. The smaller dye bath volumes in each zone, combined with the multiphase process and repeated impregnation cycles, maintain adequate dyeing capacity while significantly reducing the total amount of chemicals and water required compared to conventional large-volume single-phase systems.
Solution Approach 2:
The patent implements continuous recycling and reuse of the dye bath throughout the multiphase process. The dye bath is continuously circulated between dyeing zones and oxidation zones, and excess dye bath is recovered and reused in subsequent cycles. This continuity maximizes the utilization of the dye bath, maintaining productivity while minimizing chemical and water consumption.
3Reliability
If multiple impregnation and oxidation cycles are performed, then dye fixation and colour intensity improve, but processing time increases
Solution Approach 1:
The patent employs periodic alternating cycles of impregnation and oxidation within the same tank system. The multiphase process repeatedly cycles yarn through dyeing zones and oxidation zones multiple times in succession. This periodic action enhances dye fixation and colour intensity through cumulative effect while maintaining compact processing space and reducing overall processing time compared to traditional sequential multi-tank systems.
4Ease of operation
If traditional open-tank dyeing systems are used, then operational simplicity is maintained, but environmental sustainability deteriorates
Solution Approach 1:
The patent replaces traditional open-tank systems with a closed tank system that creates an inert environment. The closed system prevents harmful emissions to the environment while containing the dyeing process. The inert atmosphere control integrates environmental protection into the operational process, maintaining ease of operation through automated atmosphere management while eliminating the harmful factors associated with open-tank dyeing.
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 apparatus achieves improved dye fixation, reduced chemical and water consumption, lower production costs, and enhanced dyeing performance, while maintaining ecological sustainability.
Implementation Method 1
dyeing, in an inert environment, of fabrics and yarns, with indigo and other reduction dyes
Implementation Method 2
with indigo and other reduction dyes
Data Source
AI summary
A description is provided of an apparatus for dyeing a textile support comprising a single tank which is provided in its interior, in sequence, with: one first shaped cavity having a watertight function between the surrounding environment and the tank; one first internal partition wall, which is immersed in the lower part in the dye bath of the first shaped cavity for helping the watertight function; one first dyeing compartment and at least one second dyeing compartment which each comprise at least one return roller for the textile support, at least one dispensing device to dispense the dye bath on the textile support, and at least one squeezing device; a second shaped cavity containing the dye bath having a watertight function between the tank and the surrounding environment; and a second internal partition wall, which is immersed in the lower part in the dye bath of the second shaped cavity for helping the watertight.