Yarn Package Dyeing with Sequential Fluid Recirculation
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Solution Overview
Problem
Traditional machines for dyeing reels of yarn face issues with high energy consumption, non-uniform dye distribution, and poor temperature control due to high flow rates and differential pressures required for dye circulation, which affect the quality of dyeing, especially for delicate materials.
Innovation Solution
A machine that selectively and sequentially supplies dyeing fluid to groups of reels, combined with recirculation mechanisms to maintain dye and temperature uniformity, reducing the overall energy requirements and pump capacity while ensuring uniform dye distribution across all parts of the yarn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high flow rate circulation is used to ensure uniform dye distribution, then dyeing uniformity is improved, but energy consumption increases
Solution Approach 1:
The patent divides the reel holder rods into groups and subdivides each group into smaller subgroups. The circulation pump selectively supplies dyeing fluid to different subgroups in sequence rather than to all reels simultaneously. This segmentation allows the pump to maintain adequate flow rates for uniform dyeing while reducing overall energy consumption by not circulating fluid through all reels at full capacity continuously.
Solution Approach 2:
The patent implements periodic circulation where the pump operates in cycles, supplying dyeing fluid to different groups of reels at different time intervals. Each reel receives intermittent circulation rather than continuous high-flow circulation. This periodic action maintains dyeing uniformity over time while significantly reducing peak and average energy consumption compared to continuous high-flow circulation.
2Reliability
If high differential pressure is used to force dyeing fluid through material, then penetration through material is improved, but pump power requirements increase
Solution Approach 1:
By segmenting the reel groups and supplying fluid selectively to smaller subgroups at a time, the pump encounters less resistance from any single group. This reduces the differential pressure required compared to forcing fluid through all reels simultaneously, thereby reducing pump power requirements while still achieving adequate penetration through each material batch.
Solution Approach 2:
The system dynamically adjusts which reels receive dyeing fluid at any given moment, creating variable flow conditions rather than static high-pressure circulation through all reels. This dynamic selective supply allows the pump to operate at lower power levels by adapting flow distribution to actual needs of different reel groups.
3Power
If selective sequential supply to reel groups is used, then pump capacity is reduced, but dye bath circulation uniformity deteriorates
Solution Approach 1:
The patent compensates for reduced pump capacity by implementing periodic circulation through different reel groups. Each group receives thorough circulation during its designated time interval, ensuring uniform dye distribution within that group. The periodic rotation of active groups maintains overall bath uniformity despite the pump operating at lower capacity at any single moment.
Solution Approach 2:
While one subgroup of reels is being supplied with dyeing fluid, other subgroups are either receiving fluid or are in the process of absorbing dye. The system maintains continuous useful action across all reels over time, ensuring that despite selective sequential supply, all reels achieve uniform dyeing through the cumulative effect of periodic circulation.
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 solution achieves superior dyeing uniformity and reduced energy consumption, maintaining dye and temperature characteristics, allowing for efficient dyeing of both delicate and robust materials with lower power input, thus improving the overall dyeing process.
Implementation Method 1
circulation of the dye bath through the material is such as to allow the best possible distribution of the dyeing fluid on the yarn being dyed
Implementation Method 2
the circulation pump must generate a significant differential pressure, of between 0.5 bar and 1.5 bar
Implementation Method 3
Homogeneity of dye bath temperature and the concentration of colour on all parts of the yarns being dyed is normally guaranteed
Data Source
AI summary
A machine for dyeing reels of yarn and textile fibers wound on packages, including: a structure delimiting a chamber partially or fully filled with a dyeing fluid; a support immersed in the dyeing fluid; a plurality of reel-holder rods that communicate via the fluid with the support to allow the dyeing fluid to pass the support; first and second recirculation mechanisms associated with the structure, to initiate transit of the dyeing fluid in accordance with at least one set route is described. The first recirculation mechanism interposed between the chamber and the support induces the dyeing fluid to pass through the reel-holder rods and includes a pump and respective selection mechanisms to intermittently channel the dyeing fluid through the support, the reel-holder rods, and the respective reels. The second recirculation mechanism induces transit of the dyeing fluid within the chamber in accordance with at least one closed route.