Weaving machine having yarn dyeing function
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Solution Overview
Problem
Traditional yarn dyeing methods are resource-intensive, wasteful, and environmentally unfriendly due to high water usage and low dye utilization rates, with existing solutions like cheese dyeing machines still failing to optimize dye efficiency.
Innovation Solution
A weaving machine incorporating a yarn winding mechanism, a yarn coloring mechanism with hot rollers and color paper tapes for sublimation transfer printing, and a back-end system for integrating dyeing and weaving, utilizing water-free dyeing technology to directly dye and weave yarns, eliminating the need for extensive water treatment and reducing dye usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional yarn dyeing methods are used with immersion in dye solution and heating, then the yarn can be dyed, but a large amount of water is consumed and dye utilization rate is low
Solution Approach 1:
The patent extracts the dyeing function from traditional water-based immersion methods and implements it through sublimation transfer printing. Color paper tapes with pre-applied dye patterns are positioned on the yarn, and dye is transferred through heat and pressure without requiring large amounts of water, thereby reducing water consumption while maintaining precise dye application.
Solution Approach 2:
The patent replaces the mechanical immersion and heating system with a sublimation transfer printing system. Instead of immersing yarn in liquid dye solution and heating it, the system uses color paper tapes with sublimable dye that transfers to the yarn through controlled heat and pressure application, eliminating the need for water-based dyeing processes.
2Loss of substance
If traditional yarn dyeing methods are used with immersion and washing, then the yarn can be dyed, but dye utilization rate is low and resources are wasted
Solution Approach 1:
The patent applies preliminary action by pre-applying dye patterns to color paper tapes before the dyeing process. The dye is precisely positioned on the paper tape in advance, ensuring accurate dye application to the yarn without requiring subsequent washing or correction processes, thereby improving dye utilization rate.
Solution Approach 2:
The patent replaces water-based immersion and washing systems with sublimation transfer printing. The dye transfers directly from the color paper tape to the yarn through heat and pressure, eliminating the need for water-based washing processes and improving dye utilization rate by preventing dye loss in wastewater.
3Object-affected harmful factors
If traditional yarn dyeing methods are used with water washing, then the yarn can be dyed, but waste water and exhaust gas are produced
Solution Approach 1:
The patent replaces water-based washing and heating systems with sublimation transfer printing. The process uses color paper tapes with sublimable dye that transfers to the yarn through controlled heat and pressure, eliminating the generation of waste water and exhaust gas while maintaining precise dye application through the structured paper tape design.
Solution Approach 2:
The patent converts the potential harm of dye loss and waste into benefit by using sublimation transfer printing. The sublimable dye on color paper tapes transfers efficiently to the yarn through heat and pressure, converting what would be waste dye into useful colored yarn, while eliminating waste water and exhaust gas production.
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 approach significantly reduces water waste, simplifies production processes, lowers costs, and enhances efficiency by integrating dyeing and weaving, while ensuring accurate dye application and maintaining yarn tension.
Implementation Method 1
The inner layer color paper tape is configured to be pressed by the undyed yarns. The outer layer color paper tape is configured to movably abut against the undyed yarns. The inner and outer layer color paper tapes are configured to clamp therebetween the undyed yarns. inks of the inner and outer layer color paper tapes are transferred to the undyed yarns for dyeing the undyed yarns
Implementation Method 2
The squeezing device includes a closed loop belt movably pressing the packing paper against the hot roller such that inks of the inner and outer layer color paper tapes are transferred to the undyed yarns
Data Source
AI summary
A weaving machine includes a yarn winding mechanism for winding and unwinding undyed yarns, and a yarn coloring mechanism including a hot roller, inner and outer layer color paper tape winding devices for winding and unwinding inner and outer layer color paper tapes, respectively, and a packing paper winding device for winding and unwinding a packing paper. The inner and outer layer color paper tapes are configured to clamp therebetween the undyed yarns. A squeezing device includes a closed loop belt movably pressing the packing paper against the hot roller such that inks of the inner and outer layer color paper tapes are transferred to the undyed yarns. A back-end system is configured to weave or wind the dyed yarns.