Method and apparatus for digital dyeing of thread
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Solution Overview
Problem
Current methods for printing on fabric threads face issues such as color shifting due to fabric stretching and difficulty in achieving multi-color effects, as well as limitations to producing threads of single colors, often requiring specialized and expensive equipment.
Innovation Solution
A thread printing system comprising a source spool, multiple print heads connected to ink tanks, a fuser with heating rollers, and a controller to apply and fuse ink onto the thread, allowing for multi-color printing and thread winding, with optional UV curing and gas retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printing is done directly on fabric, then printing speed is improved, but color accuracy deteriorates due to fabric stretching and fiber movement
Solution Approach 1:
The fabric printing process is segmented into two independent stages: (1) printing ink onto individual thread strands before fabric formation, and (2) assembling the printed threads into fabric. This segmentation allows printing to occur on stable, non-stretching thread material rather than on the final fabric, eliminating color accuracy problems while maintaining printing speed.
Solution Approach 2:
The ink is applied to the threads in advance, before the threads are assembled into fabric. This preliminary printing action occurs on individual threads that do not stretch or move relative to each other, ensuring precise color placement that will be maintained in the final fabric product.
2Manufacturing precision
If specialized print heads and curing systems are used for thread printing, then printing quality is improved, but equipment cost increases
Solution Approach 1:
The system uses standard inkjet print heads designed for general-purpose printing, which are already widely available and cost-effective. These conventional print heads are adapted for thread printing by controlling the thread transport mechanism, eliminating the need for specialized, expensive print head hardware while maintaining printing quality.
Solution Approach 2:
The thread itself serves as the substrate that carries the ink, eliminating the need for separate fabric handling and curing systems. The thread's physical properties (tensile strength, flexibility) enable it to be printed upon and then assembled into fabric without requiring additional specialized equipment for color fixation or stabilization.
3Device complexity
If single-color printing is used on threads, then equipment complexity is reduced, but product versatility deteriorates
Solution Approach 1:
Multiple inkjet print heads capable of different colors are merged into a single integrated printing system. The controller coordinates multiple print heads to apply different colored inks to the same thread or to different threads simultaneously, enabling multi-color thread production and colorful fabric assembly from individually printed threads.
Solution Approach 2:
The controller acts as an intermediary that receives color information, determines the printing sequence and parameters, and coordinates multiple print heads and thread transport mechanisms. This intelligent mediation enables complex multi-color printing patterns without requiring proportionally complex hardware for each color combination.
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 the production of multicolored threads with stable color retention and efficient ink fusion, overcoming the limitations of single-color production and equipment costs, while allowing for flexible thread handling and integration with fabric weaving systems.
Implementation Method 1
a fuser comprising at least a first roller that is connected to a heating element. The fuser is positioned to receive the thread after the print heads apply ink to the thread so that the heat will fuse the ink to the thread
Implementation Method 2
a spring that is connected to the first frame element and the second frame element to draw the frame elements and rollers toward each other. The fuser may thus (or otherwise) be configured to pull the thread along the transport path past the print heads
Data Source
AI summary
A thread printing system includes a source spool containing thread. The system also includes various print heads, each of which is fluidly connected to an ink tank. The print heads are positioned to direct and apply ink to a segment of the thread as the thread travels along a transport path along from the source spool. The system also includes a fuser having one or more print rollers that are connected to a heating element. The fuser receives the dyed thread and fuses the ink to the thread. The system may include a controller that is configured to apply ink of different colors to different segments of the thread.