Warp transferring machine
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Solution Overview
Problem
Conventional dyeing and finishing processes in the textile industry are resource-intensive and lead to high pollutant emissions, with existing weaving machines being limited to either white or black warps, restricting machine utilization and increasing production costs due to labor-intensive and costly processes for replacing warps to achieve desired colors.
Innovation Solution
A warp transferring machine that includes a color transferring unit with a heating roller, driving shaft, separable shaft, supporting shaft, and pressing belt, which uses colored paper to transfer colors onto yarns, allowing for efficient and eco-friendly color changes without water, enabling the use of different colored warps to produce a wide range of fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional dyeing and finishing processes are used to color yarns, then the desired fabric colors can be achieved, but resource consumption increases and pollutant emissions occur
Solution Approach 1:
The patent replaces the conventional chemical dyeing process with a physical color transfer process. A heating roller heated to 80-120°C transfers color from colored paper to yarns through thermal contact, eliminating the need for chemical dyes and water-based dyeing processes. This substitution reduces resource consumption and avoids pollutant emissions associated with traditional dyeing.
Solution Approach 2:
The patent changes the working parameters from chemical concentration and water flow to temperature control. The heating roller is maintained at 80-120°C to enable color transfer without chemical reactions. This parameter change transforms the process from a chemical-intensive to a thermal-energy-intensive process, reducing environmental impact.
2Ease of operation
If white or black warps are used in weaving machines, then machine operation is simplified, but machine utilization is restricted and production costs increase due to labor-intensive warp replacement
Solution Approach 1:
The patent applies color to yarns before they are wound onto warp reels and fed into weaving machines. The color transfer process occurs upstream in the production chain, allowing yarns to be pre-colored in various hues. This preliminary action eliminates the need for labor-intensive warp replacement during weaving operations, as colored warps can be directly used without manual intervention.
Solution Approach 2:
The patent uses colored paper as a template or copy to transfer color patterns onto yarns. The colored paper serves as a master that reproduces desired color patterns on the yarn surface through thermal contact. This copying mechanism enables versatile color options without requiring physical warp replacement.
3Quantity of substance
If the density of wefts is increased to ensure color saturation in light-colored fabric, then color saturation is improved, but weaving time increases and defective products increase
Solution Approach 1:
The patent replaces the mechanical approach of increasing weft density to achieve color saturation with a thermal color transfer process. The heating roller directly imparts color to yarns at high concentration through thermal contact, achieving saturated colors without requiring increased material density. This substitution eliminates the trade-off between color saturation and weaving 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
The machine enables efficient color transfer onto yarns, reducing environmental impact and production costs, allowing for easier replacement of yarns and improved fabric quality with reduced manufacturing costs and increased comfort.
Implementation Method 1
a heating roller, a driving shaft, a separable shaft, a supporting shaft and a pressing belt. The heating roller is detachably mounted to the machine body unit, extends along the left-right direction, is driven by the machine body unit to rotate about its axis, has an outer circumferential surface, and includes a heater device for heating the outer circumferential surface
Data Source
AI summary
A warp transferring machine includes a color transferring unit, a colored paper unit and a yarn arranging unit. The color transferring unit includes a heating roller, a driving shaft, a separable shaft, a supporting shaft that are rotatable about their respective axes and a pressing belt that is looped therearound to circulate continuously. The colored paper unit and the yarn arranging unit respectively guide a colored paper and a yarn toward the heating roller such that the pressing belt presses thereagainst so as to transfer colors of the colored paper onto the yarn.