Rotating Roller Spray Dyeing for Low-Water Brassiere Processing
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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, especially when dyeing delicate items like lingerie and brassieres.
Innovation Solution
A garment dyeing machine with a rotatable roller and nozzles that spray a dye solution at raised pressure, atomizing it into nano-scale particles, using minimal water and maintaining controlled temperature and humidity within a closed container, reducing the fabric to dye solution ratio from 1:4 to 1:1.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional garment dyeing machines use large quantity of water for dyeing, then the dyeing process can be completed, but water consumption increases significantly making it environmentally unfriendly
Solution Approach 1:
The patent changes the physical state and delivery method of the dye solution from bulk liquid application to atomized spray application. The nozzle system breaks the dye solution into fine droplets, fundamentally changing how the liquid interacts with the garment surface, thereby reducing total water consumption while maintaining effective dye coverage.
Solution Approach 2:
The patent employs a nozzle system that uses pneumatic or hydraulic principles to atomize the dye solution. By applying pressure through the nozzle, the dye solution is broken into fine spray droplets that can be efficiently deposited on the garment, reducing the total volume of water needed compared to conventional immersion or bulk spraying methods.
2Quantity of substance
If conventional dyeing machines use fabric to dye solution ratio of 1:4, then adequate dye coverage is achieved, but water usage becomes excessive especially in areas with scarce water supply
Solution Approach 1:
The patent fundamentally changes the application parameter from bulk liquid delivery to atomized spray delivery. This parameter change allows the system to use much less dye solution volume while achieving adequate coverage, making the process adaptable to water-scarce regions by reducing the fabric to dye solution ratio from 1:4 to a much lower ratio.
Solution Approach 2:
The patent transitions from two-dimensional immersion or surface pooling of dye solution to three-dimensional atomized spray distribution. The atomization process creates a cloud of fine droplets that envelop the garment in three dimensions, ensuring uniform coverage with minimal total liquid volume.
3Manufacturing precision
If spray nozzle atomizes dye solution into nano-scale particles, then more even and controlled dyeing is achieved, but device complexity increases
Solution Approach 1:
The patent uses pneumatic or hydraulic pressure systems to achieve atomization, which is a well-established technology. By leveraging existing pneumatic/hydraulic principles, the system achieves nano-scale particle formation without requiring overly complex device design, balancing manufacturing precision with reasonable device complexity.
4Productivity
If the roller rotates at high speed for efficient dyeing, then productivity increases, but the control and evenness of dye application may be compromised
Solution Approach 1:
The patent uses pressurized spray nozzles to deliver the dye solution, which maintains consistent application pressure regardless of roller speed. The pneumatic/hydraulic pressure system compensates for variations in contact time at different speeds, ensuring even dye distribution even when the roller rotates at high speed for increased productivity.
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
Significantly reduces water usage and energy consumption while achieving a more even and controlled dyeing process, making it suitable for areas with limited water resources and allowing for efficient dyeing of garments like lingerie and brassieres.
Implementation Method 1
nozzles that spray a dye solution at raised pressure, atomizing it into nano-scale particles
Implementation Method 2
roller being within said container and rotatable relative to said container about an axis of rotation
Data Source
AI summary
A garment dyeing machine (10) includes 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), the garment dyeing machine having two nozzles (24) for spraying a dye solution onto the roller (22).