Transfer Dyeing Method Using Ink Rollers to Reduce Water Consumption
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Solution Overview
Problem
Traditional textile dyeing methods, such as dip dyeing and pad dyeing, consume excessive water and generate significant wastewater, posing environmental challenges and inefficiencies in dyeing processes.
Innovation Solution
A transfer dyeing method involving the use of pretreating liquids and ink transfer rollers/ribbons to apply dye ink to the fabric surface, allowing for single-sided or double-sided dyeing with reduced water consumption and improved dye fixation, using a sequence of coating, printing, pressing, and drying steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional dip dyeing or pad dyeing methods are used, then the fabric can be dyed uniformly, but water consumption is excessive and large amounts of wastewater are generated
Solution Approach 1:
The patent extracts the dyeing function from the bulk water-based dye bath and concentrates it into a waterless or low-water ink formulation. The dye is transferred directly from the ink transfer roller to the fabric surface without requiring large volumes of water for dye transport and fixation, thereby dramatically reducing water consumption while maintaining dyeing effectiveness
Solution Approach 2:
The patent changes the physical and chemical parameters of the dyeing medium from a water-based dye bath to an ink formulation with controlled viscosity and composition. The ink contains dye, resin, and other components in specific proportions that enable direct transfer to fabric without water, fundamentally altering the dyeing process parameters to eliminate water consumption
2Productivity
If traditional dyeing methods are used, then the dye can penetrate deeply into the fiber, but the process is time-consuming and less efficient
Solution Approach 1:
The patent replaces the time-consuming diffusion-based dye penetration mechanism with a mechanical transfer system. The ink transfer roller directly deposits dye onto the fabric surface under pressure, eliminating the need for prolonged soaking and diffusion processes. This mechanical substitution dramatically reduces dyeing time while maintaining effective dye deposition
Solution Approach 2:
The patent applies preliminary action by pre-coating the fabric with a pretreating liquid that enhances dye receptivity before the actual dyeing step. This pretreatment prepares the fabric surface to accept the transferred ink more effectively, ensuring good dye fixation and color uniformity without requiring extended dyeing time
3Object-generated harmful factors
If traditional dyeing methods are used, then the dye can be applied to large areas, but significant wastewater is produced
Solution Approach 1:
The patent converts the potential harm of water-based dyeing (wastewater generation) into a benefit by using a waterless ink transfer system. The ink formulation is designed to transfer efficiently without water, and any excess ink can be recovered and reused from the ink transfer roller surface, transforming what would be wastewater into a reusable resource and eliminating harmful discharge
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
This method significantly reduces water consumption and wastewater production while achieving high dye fixation rates and allowing for various dyeing patterns, such as single-color or double-sided different-color designs, addressing the environmental and efficiency concerns of traditional methods.
Implementation Method 1
transferring the ink from the printing plate roller to the fabric surface through contact
Implementation Method 2
heating the fabric with a heating unit, wherein the heating unit is disposed below the fabric
Implementation Method 3
coating a pretreating liquid on a front side of a fabric by a first pretreating anilox roller
Data Source
AI summary
A transfer dyeing method, includes: 1) coating a pretreating liquid on a front side of a fabric by a first pretreating anilox roller; 2) printing a dyeing ink on a first ink transfer roller or ink transfer ribbon by a first full-master printing plate roller; 3) transferring the dyeing ink to the front of the fabric; 4) drying the fabric and then making a back side of the fabric face to a second pretreating anilox roller; 5) coating the pretreating liquid on the back side of the fabric; 6) printing a dyeing ink that is same as or different from the dyeing ink of step 2) on a second transfer-roller or ink transfer ribbon; 7) transferring the dyeing ink to the back side of the fabric; and 8) drying the fabric, followed by color fixing, water washing and shaping.