Vacuum Suction Roller for Continuous Fabric Sublimation
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Solution Overview
Problem
Current fabric dyeing methods generate significant wastewater and are not suitable for continuous production, limiting productivity and increasing costs due to complex processes and the need for individual yarn dyeing for color patterns.
Innovation Solution
A continuous printing apparatus using a vacuum suction roller that preheats and laminates a dye-coated film onto a woven fabric, utilizing a porous surface to sublimate dye gas and transfer it onto the fabric without a dye solution, enabling eco-friendly and cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional dyeing method using dye solution is used, then fabric can be dyed, but large amount of wastewater is generated causing environmental pollution
Solution Approach 1:
The patent replaces the chemical dyeing process with a mechanical sublimation transfer process. Instead of using dye solutions that generate wastewater, the invention uses heat and pressure to transfer dye from a film directly to the fabric through sublimation, eliminating the need for liquid dye baths and subsequent washing processes that produce polluted wastewater.
Solution Approach 2:
The invention utilizes the phase transition of dye from solid to gas (sublimation) and back to solid (deposition). The dye on the film undergoes sublimation when heated, the vapor penetrates the fabric, and then re-solidifies within the fabric fibers, achieving dyeing without liquid intermediaries and eliminating wastewater generation.
2Ease of manufacture
If traditional sublimation transfer method with jig structure is used, then dyeing can be achieved, but continuous production is difficult limiting productivity
Solution Approach 1:
The patent implements continuous production by replacing the traditional batch-wise jig-based sublimation process with a continuous conveyor system. The fabric moves continuously through the heating zone while the dye transfer occurs, allowing uninterrupted processing and significantly improving productivity compared to discrete batch operations.
Solution Approach 2:
The invention introduces dynamic elements to the previously static jig system. The fabric and dye film move continuously through the processing zone on conveyors, while heating zones are positioned to interact with the moving materials. This dynamic approach enables continuous processing while maintaining the quality benefits of sublimation transfer.
3Adaptability or versatility
If individual yarn dyeing is performed before weaving for color patterns, then desired color patterns can be achieved, but process complexity increases and costs rise
Solution Approach 1:
The patent applies preliminary action by pre-coating the fabric with a receptive layer before the actual dye transfer. This preparatory step enables the subsequent continuous sublimation process to achieve complex color patterns directly on the woven fabric without requiring pre-dyed yarns, thereby simplifying the overall process while maintaining pattern versatility.
Solution Approach 2:
The invention transitions from one-dimensional yarn-level color application to two-dimensional fabric surface dyeing. By applying dye patterns directly to the fabric surface through the sublimation film in continuous motion, the system achieves color pattern versatility without the complexity of individual yarn dyeing, effectively adding a dimensional approach to pattern creation.
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 eliminates wastewater generation, facilitates high-quality, stable dyeing, and supports continuous production, reducing costs while maintaining environmental sustainability.
Implementation Method 1
the gas containing the sublimated dye on the surface of the vacuum roller
Implementation Method 2
the gas containing the sublimated dye on the surface of the vacuum roller is sucked into the vacuum suction roller through the plurality of pores
Implementation Method 3
a second heating unit positioned to be spaced from the surface of the vacuum suction roller in contact with the air permeable fabric at a certain interval to heat the air permeable fabric and the printing film
Data Source
AI summary
The present invention relates to a continuous printing apparatus using a vacuum suction roller, and it is to provide a continuous printing apparatus and method using a vacuum suction roller capable of reducing costs and improving productivity by continuously printing on the surface of a woven fabric using the vacuum suction roller.