Waterless yarn dyeing system, spray device thereof, and color development and dye fixation equipment thereof
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Solution Overview
Problem
Conventional waterless yarn dyeing systems face issues of uneven dyeing due to nozzles that cannot spray ink onto the lower sides of yarns, leading to reduced quality, and conventional dye fixation equipment consumes excessive energy and pollutes the environment with dye release, necessitating frequent maintenance.
Innovation Solution
A waterless yarn dyeing system with a spray device featuring passages that extend perpendicular to the yarns, allowing ink to be sprayed from both top and bottom sides, and a dye fixation equipment with a circulation unit to manage hot air flow and filter emissions, reducing energy consumption and pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nozzles are arranged above the yarns to spray ink, then the spray device structure is simple, but the dyeing uniformity deteriorates because the lower sides of yarns cannot be sprayed
Solution Approach 1:
The spray device is segmented into an upper body and a lower body, with multiple nozzles distributed across different locations. The upper body contains nozzles for spraying the upper sides of yarns, while the lower body contains nozzles for spraying the lower sides of yarns. This segmentation allows comprehensive coverage of both surfaces of the yarns, solving the dyeing uniformity problem while maintaining a modular and manageable structure.
Solution Approach 2:
The spray device transitions from a single-dimensional (above-only) spraying arrangement to a multi-dimensional configuration by adding a lower body with nozzles positioned below the yarns. This dimensional expansion enables ink to be sprayed from both upper and lower directions simultaneously, ensuring uniform dyeing coverage on both surfaces of the yarns.
2Reliability
If conventional heating members blow hot air to heat yarns to high temperatures, then dye fixation is achieved, but energy consumption increases significantly
Solution Approach 1:
The heating device changes the temperature parameter strategy by using a multi-layer heating structure with different temperature zones. The first heating member operates at a lower temperature (first temperature) while the second heating member operates at a higher temperature (second temperature). This parameter differentiation allows efficient heat distribution and reduces overall energy consumption while achieving the required dye fixation temperature for different yarn types.
Solution Approach 2:
The heating device implements continuous heating action through multiple heating members that simultaneously heat the yarns from different positions. The first heating member continuously provides base heating, while the second heating member supplements with additional heating power. This continuous multi-zone heating ensures uniform temperature distribution and maintains dye fixation effectiveness without energy waste from repeated heating cycles.
3Reliability
If high temperature heating is applied to fix dye on yarns, then dye fixation is achieved, but dye is released into the air causing pollution and requiring maintenance
Solution Approach 1:
The heating device changes the temperature parameter distribution by using multiple heating members with different temperature settings. The first heating member operates at a lower temperature (first temperature) suitable for initial heating, while the second heating member operates at a higher temperature (second temperature) for final fixation. This staged temperature approach achieves effective dye fixation while minimizing excessive heat that would cause dye release and air pollution.
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 system ensures even dyeing by spraying ink uniformly on both sides of yarns, reduces energy consumption, and minimizes environmental pollution by recirculating and filtering air, enhancing dye fixation and reducing maintenance costs.
Implementation Method 1
The blower is operable to transfer air from the heating space sequentially through the filter, the lower vent, and the circulation plumbing to the upper intake
Implementation Method 2
The heater unit is adapted for outputting a hot air flow to the plurality of yarns in the heating space
Implementation Method 3
a filter that is disposed between the lower vent and the heating space
Data Source
AI summary
A waterless yarn dyeing system is adapted for outputting a liquid to a plurality of yarns. The waterless yarn dyeing system includes a piece of dyeing equipment, and a piece of color development and dye fixation equipment. The dyeing equipment includes a liquid supply device, and a spray device. The spray device includes a lower body that communicates with the liquid supply device, and an upper body that communicates with the liquid supply device and that is connected to an upper side of the lower body. The color development and dye fixation equipment includes a dye fixation device that includes a body unit, a heater unit, and a circulation unit. The body unit has a heating space that is adapted for the plurality of yarns to pass therethough, a lower vent that is located below the heating space, and an upper intake that is located above the heating space.