Transfer Device for Partial Dyeing Resin Bodies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for dyeing resin bodies, such as plastic lenses, face challenges in achieving precise partial dyeing, particularly in preventing dye transfer to undyed regions and avoiding distortion due to temperature differences during the dyeing process.
Innovation Solution
A transfer device that includes a blocked chamber, an electromagnetic wave generating unit, a mask set unit, and an atmospheric pressure control unit, which allows for partial dyeing by shielding the undyed region from the electromagnetic wave and controlling atmospheric pressure to prevent unintended dye transfer, while using a mask to shield the undyed area from the electromagnetic wave generating unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resin body is heated to fix the dye in the entire surface, then the dyeing effect is improved, but the undyed region may be distorted due to temperature difference
Solution Approach 1:
The heating process is segmented into two distinct stages: (1) selective heating of only the dyed region to fix the dye, and (2) subsequent heating of the entire surface including undyed regions. This segmentation allows the dyed region to be heated without causing distortion in undyed areas, while still achieving complete dye fixation.
Solution Approach 2:
The dye transfer step is performed as a preliminary action before the fixing step. By transferring the dye to the resin body surface first, then selectively heating only the dyed regions in a subsequent step, the system achieves precise dye fixation without distorting undyed areas. The undyed regions are heated last, after the dyed regions have already been fixed.
2Shape
If the undyed region is shielded during heating, then distortion is reduced, but heat conduction may still fix dye to the undyed region
Solution Approach 1:
The heating process is divided into sequential stages with different heating zones. First, only the dyed region is heated to fix the dye while undyed regions remain cool and shielded. This temporal and spatial segmentation prevents unwanted dye fixation in undyed areas while avoiding distortion from premature heating.
Solution Approach 2:
The heating process uses periodic action with distinct phases: a first heating phase targeting only dyed regions, followed by a second heating phase that includes undyed regions. This periodic heating approach ensures precise dye fixation in dyed areas before exposing undyed areas to heat, preventing both distortion and unwanted dye transfer.
3Manufacturing precision
If the entire surface is heated for dye fixing, then dye fixation is improved, but working environment is difficult to improve
Solution Approach 1:
The conventional mechanical heating method that requires heating the entire surface is replaced with selective electromagnetic wave heating. By using electromagnetic waves that can be precisely directed and controlled, the system heats only the dyed regions without requiring complex mechanical shielding or full-surface heating apparatus, thereby improving working conditions while maintaining dye fixation efficiency.
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 accurate and efficient partial dyeing of resin bodies, reducing the risk of dye transfer to undyed regions and minimizing distortion by controlling the dyeing process with precise temperature management and shielding, thus improving the quality of the dyeing process.
Implementation Method 1
an electromagnetic wave generating unit that generates an electromagnetic wave for heating the dye adhered to the base body
Implementation Method 2
an ink containing a subliming dye is applied (printed) to a base body by a printing device (ink jet printer). Next, a transfer step of transferring the dye to the resin body is performed by sublimating the subliming dye applied to the base body
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A transfer device transfers a subliming dye from a base body to which the dye is adhered, to a resin body to be dyed. The transfer device has a blocked chamber placement unit that places the resin body inside a blocked chamber in a state where the resin body faces the base body in a non-contact manner, an electromagnetic wave generating unit that generates an electromagnetic wave for heating the dye adhered to the base body, a mask set unit that sets a mask shielding a part of a space from the electromagnetic wave generating unit to the resin body, an atmospheric pressure control unit that controls an atmospheric pressure in the blocked chamber, and a controller. The mask is set for partial dyeing, and the electromagnetic wave generating unit heats the dye of the base body in a state where the atmospheric pressure in the blocked chamber is lowered.