WATERLESS YARN DYEING SYSTEM, YARN SEPARATION EQUIPMENT THEREOF, AND DYEING EQUIPMENT THEREOF
20260035848 ยท 2026-02-05
Inventors
Cpc classification
D06B23/205
TEXTILES; PAPER
D06B2700/36
TEXTILES; PAPER
International classification
D06B23/06
TEXTILES; PAPER
Abstract
A waterless yarn dyeing system includes a piece of yarn separation equipment and a piece of dyeing equipment. The yarn separation equipment is adapted for separating a plurality of yarns. The dyeing equipment is adapted for outputting an ink to the yarns, and includes an ink supply device, an inkjet device, and at least two pump units. The ink supply device includes two ink containers that are adapted for holding the ink, at least two ink supply tubes that are respectively connected to the ink containers, and an ink tank that is connected to the at least two ink supply tubes. The at least two pump units are respectively disposed on the at least two ink supply tubes. Each of the at least two pump units includes an input pump and an output pump that are operable to adjust a flow rate of the ink, and a temporary storage box.
Claims
1. A waterless yarn dyeing system comprising: a piece of yarn separation equipment adapted for separating a plurality of yarns, and including a yarn separation plate, the yarn separation plate having a top surface, and a plurality of separation grooves that are formed in the top surface, that extend in a first direction, that are spaced apart from each other in a second direction, and that are adapted for the plurality of yarns to be spaced apart from each other and to be disposed thereon, the second direction being perpendicular to the first direction; and a piece of dyeing equipment adapted for outputting an ink to the plurality of yarns, and including an ink supply device that includes two ink containers which are adapted for holding the ink, at least two ink supply tubes which are respectively connected to the ink containers, and an ink tank which is connected to the at least two ink supply tubes, an inkjet device that communicates with the ink tank and that is adapted for outputting the ink to the plurality of yarns, and at least two pump units that are respectively disposed on the at least two ink supply tubes, each of the at least two pump units including an input pump that is operable to adjust a flow rate of the ink, a temporary storage box that communicates with the input pump, and an output pump that is operable to adjust the flow rate of the ink and that communicates with the temporary storage box, for each of the at least two pump units, the input pump, the temporary storage box, and the output pump being adapted for the ink to flow therethrough in sequence.
2. The waterless yarn dyeing system as claimed in claim 1, further comprising a piece of yarn winding equipment connected downstream of the piece of dyeing equipment, the piece of yarn winding equipment having a plurality of yarn pass eyelets that are adapted for the plurality of yarns to pass therethrough, and a winder unit, the winder unit having a winder frame, a plurality of frame eyelets that are disposed on the winder frame, a plurality of yarn winders that are disposed on the winder frame, and an electric motor subunit that is disposed on the winder frame, the plurality of yarn winders being driven by the electric motor subunit to rotate so as to wind the plurality of yarns.
3. A piece of dyeing equipment adapted for outputting an ink to a plurality of yarns, the piece of dyeing equipment comprising: an ink supply device including two ink containers that are adapted for holding the ink, at least two ink supply tubes that are respectively connected to the ink containers, and an ink tank that is connected to the at least two ink supply tubes; an inkjet device communicating with the ink tank and adapted for outputting the ink to the plurality of yarns; and at least two pump units respectively disposed on the at least two ink supply tubes, each of the at least two pump units including an input pump that is operable to adjust a flow rate of the ink, a temporary storage box that communicates with the input pump, and an output pump that is operable to adjust the flow rate of the ink and that communicates with the temporary storage box, for each of the at least two pump units, the input pump, the temporary storage box, and the output pump being adapted for the ink to flow therethrough in sequence.
4. The piece of dyeing equipment as claimed in claim 3, wherein the temporary storage boxes of the at least two pump units are connected upstream of the ink tank, and are located at a same height.
5. The piece of dyeing equipment as claimed in claim 3, wherein each of the at least two pump units is connected to a respective one of the ink containers via the respective one of the at least two ink supply tubes, and is closer to the ink tank than the respective one of the ink containers.
6. The piece of dyeing equipment as claimed in claim 3, further comprising an ink mixture control unit, each of the at least two pump units further including a liquid level indicator that is disposed on the temporary storage box thereof, the ink mixture control unit being electrically coupled to the input pump, the output pump, and the liquid level indicator of each of the at least two pump units, and being operable to control the flow rate of the ink that flows through the input pump and the output pump of each of the at least two pump units so that a liquid level of the ink in the temporary storage box of each of the at least two pump units is kept at a target level.
7. The piece of dyeing equipment as claimed in claim 3, further comprising a stir unit disposed in the ink tank, the stir unit being adapted for stirring the ink that flows into the ink tank.
8. The piece of dyeing equipment as claimed in claim 3, further comprising an ink temperature control unit and an ink mixture control unit, the ink temperature control unit including an ink heater that is disposed in the ink tank and that is adapted for heating the ink which flows into the ink tank, and an ink temperature sensor that is disposed in the ink tank and that is adapted for measuring a temperature of the ink in the ink tank, the ink mixture control unit being electrically coupled to the ink heater and the ink temperature sensor, and being operable to control the ink heater to heat the ink in the ink tank to a target temperature according to the temperature of the ink in the ink tank that is measured by the ink temperature sensor.
9. A piece of yarn separation equipment adapted for separating a plurality of yarns, the piece of yarn separation equipment comprising: a yarn separation plate having a top surface, and a plurality of separation grooves that are formed in the top surface, that extend in a first direction, that are spaced apart from each other in a second direction, and that are adapted for the plurality of yarns to be spaced apart from each other and to be disposed thereon, the second direction being perpendicular to the first direction.
10. The piece of yarn separation equipment as claimed in claim 9, further comprising a plate heater disposed on the yarn separation plate and operable to heat the yarn separation plate.
11. The piece of yarn separation equipment as claimed in claim 9, wherein the plurality of separation grooves are respectively defined by a plurality of groove surfaces, any two adjacent ones of the plurality of groove surfaces being connected by a rounded surface.
12. The piece of yarn separation equipment as claimed in claim 9, further comprising a cover plate that is disposed on the yarn separation plate and that covers the plurality of separation grooves.
13. The piece of yarn separation equipment as claimed in claim 9, further comprising at least one yarn separation roller connected upstream of the yarn separation plate, an actuation unit operable to drive the at least one yarn separation roller to rotate, and a yarn separation control unit electrically coupled to the actuation unit, the at least one yarn separation roller being formed with a plurality of annular grooves that are spaced apart from each other and that are adapted for the plurality of yarns to be spaced apart from each other and to be disposed thereon, the yarn separation control unit being operable to receive data of a conveying speed of the plurality of yarns and to control the actuation unit according to the data of the conveying speed of the plurality of yarns so that the actuation unit drives the at least one yarn separation roller to rotate at a speed that matches the conveying speed of the plurality of yarns.
14. The piece of yarn separation equipment as claimed in claim 13, wherein the at least one yarn separation roller includes a plurality of yarn separation rollers that are adapted for the plurality of yarns to wind therearound, thereby changing an advancing direction of the plurality of yarns, the actuation unit being operable to drive the plurality of yarn separation rollers to rotate.
15. The piece of yarn separation equipment as claimed in claim 14, further comprising a yarn arrangement unit connected upstream of the plurality of yarn separation rollers, the yarn arrangement unit being wavy and including a plurality of yarn arrangement plates, any two adjacent ones of the plurality of yarn arrangement plates being pivotably connected to each other, each of the plurality of yarn arrangement plates including a plurality of yarn separation teeth that are spaced apart from each other, the plurality of yarn separation teeth of each of the plurality of yarn arrangement plates defining a plurality of gaps that are adapted for the plurality of yarns to pass therethrough, a length of the yarn arrangement unit being adjustable to change a distance between any two adjacent ones of the plurality of yarns.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other features and advantages of the disclosure will become apparent in the following detailed description of the embodiment(s) with reference to the accompanying drawings. It is noted that various features may not be drawn to scale.
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DETAILED DESCRIPTION
[0027] Before the disclosure is described in greater detail, it should be noted that where considered appropriate, reference numerals or terminal portions of reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.
[0028] It should be noted herein that for clarity of description, spatially relative terms such as top, bottom, upper, lower, on, above, over, downwardly, upwardly and the like may be used throughout the disclosure while making reference to the features as illustrated in the drawings. The features may be oriented differently (e.g., rotated 90 degrees or at other orientations) and the spatially relative terms used herein may be interpreted accordingly.
[0029] Referring to
[0030] The yarn feeding equipment 100 includes a yarn feeding roller 101 that is wound around by the yarns (S). The yarn feeding roller 101 is operable to rotate so as to output the yarns (S).
[0031] Referring to
[0032] In
[0033] The yarn separation reed 12 has a plurality of reed gaps 121 that extend in the up-down direction (Z), and that are spaced apart from each other in the second direction (Y). The reed gaps 121 are adapted for separating the yarns (S).
[0034] The yarn separation roller 13 is connected downstream of the yarn separation reed 12 along an advancing direction of the yarns (S), and is adapted for conveying the yarns (S) via rotation thereof. The yarn separation roller 13 extends in the second direction (Y), and includes a roller body 131 that is rotatable relative to the yarn separation base 11. The roller body 131 is formed with a plurality of annular grooves 132 that are spaced apart from each other in the second direction (Y). The annular grooves 132 are adapted for the yarns (S) to be spaced apart from each other and to be disposed thereon. A number of the annular grooves 132 is less than a number of the reed gaps 121.
[0035] The yarn separation plate 14 is disposed on the yarn separation base 11, and is connected downstream of the yarn separation roller 13 along the advancing direction of the yarns (S). The yarn separation plate 14 has a top surface 141, and a plurality of separation grooves 142 that are formed in the top surface 141, and that are adapted for the yarns (S) to be spaced apart from each other and to be disposed thereon. The separation grooves 142 extend in the first direction (X) and are spaced apart from each other in the second direction (Y). The separation grooves 142 are respectively defined by a plurality of groove surfaces 143 (see
[0036] When the yarns (S) are conveyed, a specific textile auxiliary or solvent may be poured into the separation grooves 142 to help dye the yarns (S). In one embodiment, the yarn separation plate 14 may be formed with a plurality of through holes (not shown) that respectively communicate with the separation grooves 142, and that are located at a downstream section of the yarn separation plate 14 along the advancing direction of the yarns (S). Superfluous textile auxiliaries or solvents in the separation grooves 142 can be drawn out by a piece of negative pressure equipment (not shown) through the through holes.
[0037] The yarn separation temperature control unit 15 includes a plate heater 151 that is disposed on the yarn separation plate 14 and that is operable to heat the yarn separation plate 14, and a plate temperature sensor 152 that is disposed on the yarn separation plate 14. The plate heater 151 is configured to be an electric tubular heater or an electric heating plate.
[0038] The actuation unit 16 is disposed on the yarn separation base 11, and includes a transmission belt 161 that at least partially surrounds the roller body 131 of the yarn separation roller 13, and a motor 162 that is disposed on the yarn separation base 11 and that is coupled to the transmission belt 161. The motor 162 is operable to drive the transmission belt 161 to rotate so that the transmission belt 161 drives the roller body 131 of the yarn separation roller 13 to rotate.
[0039] The yarn separation control unit 17 is electrically coupled to the plate heater 151, the plate temperature sensor 152, and the motor 162. The yarn separation control unit 17 is operable to receive data of a temperature of the yarn separation plate 14 that is detected by the plate temperature sensor 152, and to control the plate heater 151 according to the data of the temperature of the yarn separation plate 14 so that the plate heater 151 heats up the yarn separation plate 14 to a target temperature. The yarn separation plate 14 that is heated up heats up the yarns (S) that are in the separation grooves 142 evenly, and dehydrates the yarns (S), thereby making the yarns (S) dry and fluffy. The target temperature may range from about 35 degrees Celsius to about 80 degrees Celsius.
[0040] The yarn separation control unit 17 is operable to receive data of a conveying speed of the yarns (S) from a sensor (not shown) that is disposed on the yarn feeding equipment 100 or the yarn winding equipment 500, and to control a rotational speed of the motor 162 of the actuation unit 16 according to the data of the conveying speed of the yarns (S) so that the motor 162 drives the roller body 131 to rotate at a speed that matches the conveying speed of the yarns (S). Therefore, tension of the yarns (S) is kept stable, and a risk that the yarns (S) may break is reduced. In this embodiment, the yarn separation control unit 17 may be a programmable logic controller (PLC), or other types of controllers.
[0041] Referring to
[0042] The ink supply device 2 is operable for supplying different colored inks, and includes a plurality of ink containers 21, a plurality of ink supply tubes 22 that are respectively connected to the ink containers 21, an ink tank 23 that is connected downstream of the ink containers 21 and that is connected to the ink supply tubes 22, a stir unit 24 that is disposed in the ink tank 23, an ink temperature control unit 25 that is disposed in the ink tank 23, and a duct module 26 that interconnects the ink tank 23 and the inkjet device 3. The ink containers 21 are adapted for holding the ink. It is noted that the meaning of the term the ink as used throughout the disclosure may be different based on the context, and may be, for example, the colored/uncolored ink in one/each of the ink containers 21, or a mixture of the colored/uncolored inks (i.e., a mixed ink).
[0043] In this embodiment, a number of the ink containers 21 is five. Four of the ink containers 21 respectively hold four different colored inks that correspond to four colors of the CMYK color model, and the remaining one of the ink containers holds a clear ink. The four colors of the CMYK color model are cyan, magenta, yellow, and black. In some embodiments, the number of the ink containers 21 and the colors of the inks are not limited. For example, a user may use three ink containers 21 to hold three different colored inks that correspond to three colors of the RGB color model, in which R represents red, G represents green, and B represents blue.
[0044] The stir unit 24 is adapted for stirring the ink that flows into the ink tank 23, and includes an impeller 241 that is disposed in the ink tank 23, and a motor 242 that is disposed in the ink tank 23 and that is operable for driving the impeller 241 to rotate. The ink temperature control unit 25 includes an ink heater 251 that is disposed in the ink tank 23 and that is adapted for heating the ink which flows into the ink tank 23, and an ink temperature sensor 252 that is disposed in the ink tank 23. The ink heater 251 is configured to be an electric tubular heater or an electric heating plate. The ink temperature sensor 252 is adapted for measuring a temperature of the ink in the ink tank 23. The duct module 26 includes a plurality of ink output ducts 261 that interconnect the ink tank 23 and the inkjet device 3.
[0045] Referring to
[0046] The lower body 31 has a first inner surface 311 that faces the upper body 32, a first outer surface 312 that is opposite to the upper body 32 in the up-down direction (Z), a plurality of lower grooves 313 that extend in the first direction (X), that are spaced apart from each other in the second direction (Y), and that are formed in the first inner surface 311, two lower channel units 314 that are spaced apart from each other in the first direction (X), and a plurality of drainage channels 316. Each of the drainage channels 316 extends from the first outer surface 312 to a respective one of the lower grooves 313. Each of the lower channel units 314 has a plurality of lower channels 315, each of which extends from the first outer surface 312 to a respective one of the lower grooves 313.
[0047] The drainage channels 316 are disposed upstream of the lower channels 315.
[0048] The upper body 32 has a second inner surface 321 that abuts against the first inner surface 311 of the lower body 31, a second outer surface 322 that is opposite to the lower body 31 in the up-down direction (Z), a plurality of upper grooves 323 that extend in the first direction (X), that are spaced apart from each other in the second direction (Y), and that are formed in the second inner surface 321, and two upper channel units 324 that are spaced apart from each other in the first direction (X). Each of the upper channel units 324 has a plurality of upper channels 325, each of which extends from the second outer surface 322 to a respective one of the upper grooves 323. The upper channel units 324 respectively correspond in position to the lower channel units 314. The upper channels 325 of the upper channel units 324 respectively face the lower channels 315 of the lower channel units 314 in the up-down direction (Z).
[0049] The upper grooves 323 respectively face the lower grooves 313. The lower body 31 and the upper body 32 cooperatively define a plurality of passages 34 that extend in the first direction (X), and that are spaced apart from each other in the second direction (Y). Specifically, each of the lower grooves 313 cooperates with the respective one of the upper grooves 323 to form a respective one of the passages 34. The passages 34 communicate with the ink supply device 2, and are adapted for the yarns (S) to respectively pass therethrough. Each of the passages 34 communicates with a respective one of the upper channels 325 of each of the upper channel units 324, and with a respective one of the lower channels 315 of each of the lower channel units 314.
[0050] The nozzles 33 are respectively disposed on the upper channels 325 of the upper channel units 324 and the lower channels 315 of the lower channel units 314, and are respectively connected to the ink output ducts 261. Each of the nozzles 33 is threadedly connected to the lower body 31 or the upper body 32, and is adapted for outputting the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to one of the yarns (S) that are in the passages 34. Specifically, in this embodiment, for the nozzles 33 that are respectively disposed on the upper channels 325 of one of the upper channel units 324, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the upper channels 325 of another one of the upper channel units 324, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the lower channels 315 of one of the lower channel units 314, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the lower channels 315 of another one of the lower channel units 314, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. It is noted that the nozzles 33 may be inkjet structures that are different from what is disclosed in this embodiment. In some embodiments, the nozzles 33 may be printheads, atomizers, thermal printheads, direct injection printheads, or piezo inkjet devices, and may not be limited thereto.
[0051] Referring to
[0052] Referring to
[0053] For each of the pump units 5, the input pump 51, the temporary storage box 52, and the output pump 53 are disposed on a frame (not shown) following a flow direction of the ink. In this embodiment, the input pumps 51 of the pump units 5 and the output pumps 53 of the pump units 5 are high-precision micro pumps. In some embodiments, the input pumps 51 and the output pumps 53 may be peristaltic pumps, gear pumps, screw pumps, servo pumps, or piezoelectric pumps, but may not be limited thereto.
[0054] The temporary storage boxes 52 of the pump units 5 that are disposed on the ink supply tubes 22 are connected upstream of the ink tank 23, and are located at a same height. The temporary storage boxes 52 of the pump units 5 that are disposed on the ink output ducts 261 are connected upstream of the upper channels 325, or the lower channels 315. The temporary storage boxes 52 of the pump units 5 that are disposed on the ink output ducts 261 and that are connected upstream of the upper channels 325 are located at a same height. The temporary storage boxes 52 of the pump units 5 that are disposed on the ink output ducts 261 and that are connected upstream of the lower channels 315 (see
[0055] Referring to
[0056] The ink mixture control unit 6 is operable to control a flow rate of the ink that flows through the input pump 51 and the output pump 53 of each of the pump units 5 (i.e., the input pump 51 and the output pump 53 of each of the pump units 5 are operable to adjust the flow rate of the ink) so that a liquid level of the ink in the temporary storage box 52 of each of the pump units 5 is kept at a fixed value. Therefore, an ink pressure of the ink that flows into the output pump 53 of each of the pump units 5 is standardized. Moreover, the user may choose to adjust the flow rate of the ink that flows into the input pump 51 and the output pump 53 of each of the pump units 5 manually, and to eyeball the scale 55 of each of the pump units 5 to keep the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 within a certain range.
[0057] The ink mixture control unit 6 is operable to control the ink heater 251 to heat the ink in the ink tank 23 to a target temperature according to the temperature of the ink in the ink tank 23 that is measured by the ink temperature sensor 252, thereby increasing an efficiency of dyeing and color evenness. For example, nylon fibers start to absorb the ink when the temperature of the ink reaches 40 degrees Celsius, and a dyeing rate increases as the temperature increases. When the temperature of the ink reaches 100 degrees Celsius, the ink may be completely absorbed by the nylon fibers, thereby increasing the color evenness in dyeing.
[0058] Referring to
[0059] The yarn winding equipment 500 is connected downstream of the color development and dye fixation equipment 400 (i.e., downstream of the dyeing equipment 300), and is adapted for winding the yarns (S).
[0060] A detailed description of an ink mixing process of the dyeing equipment 300 of the waterless yarn dyeing system is given below.
[0061] The ink mixing process begins at step S1, where an image processing software is used to analyze a target color card or an image file so as to obtain color values of the four colors of the CMYK color model for a desired color of a mixed ink. In this embodiment, the image processing software is Adobe Photoshop.
[0062] The ink mixing process proceeds to step S2, where a colored ink is urged to flow into the ink tank 23 via the ink containers 21.
[0063] The ink mixing process proceeds to step S3, where one of the passages 34 is defined to be a designated passage 34 (see
[0064] The ink mixing process proceeds to step S4, where one of the yarns (S) is defined to be a target yarn (S), and the target yarn (S) is urged to pass through the designated passage 34 at a yarn conveying speed.
[0065] The ink mixing process proceeds to step S5, where the input pump 51 and the output pump 53 of the designated pump unit 5 are turned on and adjusted to keep the liquid level of the colored ink in the temporary storage box 52 of the designated pump unit 5 at a target level (i.e., the ink mixture control unit 6 controls the flow rate of the colored ink that flows through the input pump 51 and the output pump 53 of the designated pump unit 5 so that the liquid level of the colored ink in the temporary storage box 52 of the designated pump unit 5 is kept at the target level). In addition, the target yarn (S) absorbs the colored ink enough to reach a maximum saturation. At this time, the flow rate of the colored ink that flows through the output pump 53 of the designated pump unit 5 is defined to be a designated output flow rate.
[0066] The maximum saturation represents a maximum amount of the colored ink that the target yarn (S) can absorb per unit length. When an amount of the colored ink that is absorbed by the target yarn (S) reaches exactly the maximum saturation, the target yarn (S) is dyed evenly. When the amount of the colored ink that is absorbed by the target yarn (S) is less than the maximum saturation, a color of the target yarn (S) is discontinuous. When the amount of the colored ink that is absorbed by the target yarn (S) is more than the maximum saturation, the target yarn (S) may sweat, or the colored ink may drip down the target yarn (S).
[0067] Therefore, when the user evaluates the amount of the colored ink that is absorbed by the target yarn (S) as being not too little or too much by visual inspection, the user may determine that the amount of the colored ink that is absorbed by the target yarn (S) has reached the maximum saturation. The maximum saturation changes according to thickness, materials, or moisture contents of different yarns. Via the abovementioned steps, an accurate maximum saturation of the yarns (S) may be obtained, thereby obtaining a specific flow rate of the colored ink that has to be outputted to the target yarn (S) when the target yarn (S) advances at the yarn conveying speed.
[0068] The ink mixing process proceeds to step S6, where the input pump 51 and the output pump 53 that communicate with the clear ink temporary storage box 52 and that are respectively connected upstream and downstream of the clear ink temporary storage box 52 are turned on, and the input pump 51 and the output pump 53 of the designated pump unit 5 are turned on so as to flush the corresponding ink supply tube 22, the ink tank 23, and the corresponding ink output duct 261 with the clear ink. When the clear ink has washed away the residual colored ink and when the target yarn (S) is saturated with only the clear ink, the input pump 51 and the output pump 53 that communicate with the clear ink temporary storage box 52 are turned off.
[0069] The ink mixing process proceeds to step S7, where the input pumps 51 that respectively communicate with the colored ink temporary storage boxes 52 and that are respectively connected upstream of the colored ink temporary storage boxes 52 are turned on and adjusted, and the output pumps 53 that respectively communicate with the colored ink temporary storage boxes 52 and that are respectively connected downstream of the colored ink temporary storage boxes 52 are turned on and adjusted to keep the liquid level of the colored ink in each of the colored ink temporary storage boxes 52 at a target level (i.e., the ink mixture control unit 6 controls the flow rate of the colored ink that flows through the input pumps 51 and the output pumps 53 which communicate with the colored ink temporary storage boxes 52 so that the liquid level of the colored ink in each of the colored ink temporary storage boxes 52 is kept at the target level). The four different colored inks in the colored ink temporary storage boxes 52 are outputted to the ink tank 23 according to the color values obtained in step S1.
[0070] The ink mixing process proceeds to step S8, where the input pump 51 and the output pump 53 that communicate with the clear ink temporary storage box 52 and that are respectively connected upstream and downstream of the clear ink temporary storage box 52 are turned on and adjusted to keep the liquid level of the clear ink in the clear ink temporary storage box 52 at a target level (i.e., the ink mixture control unit 6 controls the flow rate of the clear ink that flows through the input pump 51 and the output pump 53 which communicate with the clear ink temporary storage box 52 so that the liquid level of the clear ink in the clear ink temporary storage box 52is kept at the target level). At the time the user evaluates that color concentration of the mixed ink in the ink tank 23 matches the desired color by visual inspection, the flow rate of the clear ink that flows through the output pump 53 which communicates with the clear ink temporary storage box 52, and the flow rates of the different colored inks that flow through the output pumps 53 which respectively communicate with the colored ink temporary storage boxes 52, are defined to be ink mixture flow rates.
[0071] The ink mixing process proceeds to step S9, where the input pumps 51 and the output pumps 53 of the pump units 5 that are respectively disposed on the ink supply tubes 22 are turned off, and data of the target levels, the designated output flow rate, and the ink mixture flow rates are stored in the ink mixture control unit 6.
[0072] The ink mixing process proceeds to step S10, where the ink mixture control unit 6 controls the pump units 5 to output the inks to the ink tank 23 according to the abovementioned data for mixing the inks. When the inks are mixed, the stir unit 24 stirs the mixed ink continuously, and the ink heater 251 heats the mixed ink to a specific temperature.
[0073] After the ink mixing process, a dyeing process of the waterless yarn dyeing system is performed. A detailed description of the dyeing process is given below.
[0074] The yarn feeding roller 101 rotates so as to output the yarns (S).
[0075] The yarns (S) pass through the yarn separation reed 12, the yarn separation roller 13, and the yarn separation plate 14 sequentially, and then respectively enter the passages 34.
[0076] The nozzles 33 of the inkjet device 3 that have to output the mixed ink are set up, and the yarns (S) are urged to respectively pass through the passages 34 at the yarn conveying speed. The ink mixture control unit 6 distributes the mixed ink in the ink tank 23 to the nozzles 33 according to the maximum saturation so as to dye the yarns (S) in the passages 34 that correspond in position to the nozzles 33. In addition, the ink mixture control unit 6 controls the flow rate of the mixed ink that flows through the input pump 51 and the output pump 53 of each of the pump units 5 that are disposed on the ink output ducts 261 so that the liquid level of the mixed ink in the temporary storage box 52 of each of the pump units 5 that are disposed on the ink output ducts 261 is kept at a fixed value. Superfluous mixed ink in the passages 34 is drawn out by the suction member 41 through the drainage channels 316 and the drainage ducts 42.
[0077] When the mixed ink in the ink tank 23 is about to run out, the input pumps 51 and the output pumps 53 of the pump units 5 that are disposed on the ink output ducts 261 are turned off, and then the abovementioned ink mixing process is performed again for mixing inks.
[0078] For each of the passages 34, the user may choose the nozzles 33 that are disposed on the respective one of the upper channels 325 of one of the upper channel units 324 and a corresponding one of the lower channels 315 which faces the respective one of the upper channels 325 of the one of the upper channel units 324 (i.e., two of the nozzles 33 for each of the passages 34) to output the mixed ink for dyeing the respective one of the yarns (S), or may choose the nozzles 33 that are disposed on the respective one of the upper channels 325 of each of the upper channel units 324 and the respective one of the lower channels 315 of each of the lower channel units 314 (i.e., all of the four nozzles 33 for each of the passages 34) to output the mixed ink for dyeing the respective one of the yarns (S) more completely and evenly. It is noted that no matter how many nozzles 33 the user chooses for each of the passages 34, a sum of the flow rates of the mixed ink that flows through the chosen nozzles 33 has to match the designated output flow rate so that the respective one of the yarns (S) may absorb enough mixed ink to reach the maximum saturation.
[0079] The yarns (S) enter the color development and dye fixation equipment 400 after passing through and being dyed in the inkjet device 3. The color development and dye fixation equipment 400 heats and dries the yarns (S) with the hot air so as to achieve the color development of the mixed ink on the yarns (S) and the dye fixation.
[0080] The yarn winding equipment 500 winds the yarns (S) that pass through the color development and dye fixation equipment 400 so that the yarns (S) wind around the yarn winding equipment 500 and are collected by the yarn winding equipment 500.
[0081] In this embodiment, each of the passages 34 communicates with two of the upper channels 325 and with two of the lower channels 315, but is not limited thereto. Because the nozzles 33 that are disposed on the upper channels 325 output the mixed ink by dripping the mixed ink, when the user wants to enhance the color evenness of the yarns (S) and prevent the color of the yarns (S) from being discontinuous, each of the passages 34 may be arranged to communicate with more than two of the upper channels 325 or more than two of the lower channels 315 (i.e., the upper body 32 may have more than two upper channel units 324, or the lower body 31 may have more than two lower channel units 314) and additional nozzles 33 may be disposed on the additional upper channels 325/lower channels 315 according to actual requirements to output more mixed ink.
[0082] In one embodiment, the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 may be set to have an upper limit and a lower limit, and the ink mixture control unit 6 is operable to keep the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 between the upper limit and the lower limit.
[0083] When the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 is kept within a predetermined range, it means that the ink pressure of the ink that flows from the temporary storage box 52 of each of the pump units 5 into the output pump 53 of the pump unit 5 is kept within a specific range. Therefore, for each of the pump units 5, by virtue of the temporary storage box 52, the ink pressure of the ink that flows into the output pump 53 is stable, which makes the flow rate of the ink that is outputted by the output pump 53 accurate and stable, thereby minimizing flow variation.
[0084] Consequently, by virtue of the flow rate of the ink that flows from the pump units 5 to the ink tank 23 being controlled to be accurate, precise, and stable according to the color values, quality of color mixing is high and stable. Moreover, by virtue of the amount of the mixed ink that is outputted by the inkjet device 3 to the yarns (S) being controlled to be accurate, precise, and stable, the yarns (S) are ensured to reach exactly and stay at the maximum saturation, thereby enhancing quality of dyeing.
[0085] It is noted that a structure of the inkjet device 3 may be modified so as to output the ink to a different object that is to be dyed. Accuracy of the color mixing may still be achieved, and the amount of the mixed ink that is outputted by the inkjet device 3 to the different object to be dyed may still be controlled to be accurate, precise, and stable.
[0086] Referring to
[0087] Referring to
[0088] Referring to
[0089] It is noted that in one embodiment, the yarn separation equipment 200 may further include the yarn arrangement unit 19. In one embodiment, the yarn separation equipment 200may further include the yarn separation rollers 13.
[0090] Referring to
[0091] Therefore, the yarn winding equipment 500 is capable of separating the yarns (S) evenly and collecting the evenly-separated yarns (S) with the yarn winders 505 thereof. A conventional process in which yarns that randomly wind around yarn winders have to be transported to another yarn separation device to be evenly separated may be omitted. Intricacy of equipment in a waterless dyeing system and space that all equipment in the waterless dyeing system has to occupy are greatly reduced, thereby increasing land use efficiency and reducing cost of the equipment.
[0092] Advantages of the waterless yarn dyeing system according to the present disclosure can be summarized as follows.
[0093] 1. By virtue of the pump units 5 including the temporary storage boxes 52 that hold part of the ink, and by virtue of the input pump 51 and the output pump 53 of each of the pump units 5 being operable to adjust the flow rate of the ink, the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 is kept at a certain level, and the ink pressure of the ink that flows into the temporary storage box 52 of each of the pump units 5 to the output pump 53 of the pump unit 5 is standardized. Therefore, even if the ink pressure of the ink that flows out from any one of the ink containers 21 or the ink tank 23 changes or if lengths of the ink supply tubes 22/the ink output ducts 261 are different, the flow rate of the ink that flows into the ink tank 23 or the passages 34 may still be precisely controlled by the pump units 5, thereby minimizing the flow variation of the ink and enhancing the quality and the accuracy of the color mixing, and the quality of dyeing. In addition, the yarns (S) are ensured to absorb enough ink to reach exactly and stay at the maximum saturation, thereby preventing the yarns (S) from absorbing insufficient or excessive ink, and improving quality of the dyed yarns (S).
[0094] 2. By virtue of the temporary storage boxes 52 that are connected upstream of the ink tank 23 being located at the same height, the ink pressure of the ink that flows into the output pumps 53 which are connected upstream of the ink tank 23 is ensured to be consistent. Therefore, the flow rate of the ink that flows into the ink tank 23 is stable and precisely controlled, which minimizes the flow variation of the ink and ensures that the colored inks are stably outputted to the ink tank 23 according to the color values. By virtue of the temporary storage boxes 52 that are connected upstream of the upper channels 325 being located at the same height, the ink pressure of the ink that flows into the output pumps 53 which are connected upstream of the upper channels 325 is ensured to be consistent. Therefore, the flow rate of the ink that flows into the upper channels 325 is stable and precisely controlled, which minimizes the flow variation of the ink. By virtue of the temporary storage boxes 52 that are connected upstream of the lower channels 315 being located at the same height, the ink pressure of the ink that flows into the output pumps 53 which are connected upstream of the lower channels 315 is ensured to be consistent. Therefore, the flow rate of the ink that flows into the lower channels 315 is stable and precisely controlled, which minimizes the flow variation of the ink.
[0095] 3. By virtue of each of the passages 34 confining the respective one of the yarns (S) to a limited space, and by virtue of the nozzles 33 outputting the ink to both a top side and a bottom side of each of the yarns (S), evenness of spray of the ink is greatly enhanced, and the ink is prevented from spreading to an external environment. Therefore, even though the yarns (S) may rotate or vibrate when they are conveyed, each of the yarns (S) is ensured to be soaked in the ink in the respective one of the passages 34, and absorption of the ink is ensured to be optimized, thereby preventing waste of the ink.
[0096] 4. By virtue of the stir unit 24 and the ink heater 251, the colored inks that flow into the ink tank 23 may be thoroughly mixed and the mixed ink in the ink tank 23 may have a uniform temperature. Therefore, properties of the mixed ink in the ink tank 23, for example, temperature, concentration, and viscosity, are kept uniform throughout the ink tank 23, which keeps the concentration and the viscosity of the mixed ink outputted to different yarns (S) consistent. The yarns (S) are thus ensured to have the same quality of dyeing.
[0097] 5. By virtue of the yarn separation reed 12 separating the yarns (S), positions of the yarns (S) are limited, which prevents the yarns (S) from crossing each other or overlapping. By virtue of the yarn separation roller 3 conveying the yarns (S) via the rotation thereof, the yarns (S) are prevented from rubbing against the roller body 131 of the yarn separation roller 3 and wearing. The tension of the yarns (S) is kept stable, and the yarns (S) are prevented from pilling or breaking.
[0098] 6. By virtue of the yarn separation rollers 13, the advancing direction of the yarns (S) may be changed. Furthermore, an angle of deflection of the advancing direction of the yarns (S) may be 30 degrees, 45 degrees, 90 degrees, 180 degrees, or 200 degrees, which makes the yarn separation equipment 200 suitable for dyeing systems or weaving systems with different structures.
[0099] 7. By virtue of the separation grooves 142 of the yarn separation plate 14 extending in the first direction (X), when the yarns (S) are located at the separation grooves 142 and are in contact with the yarn separation plate 14, stress concentration may be reduced, which prevents the yarns (S) from wearing, pilling or breaking. Moreover, the yarns (S) may respectively enter the passages 34 while being spaced apart from each other and in alignment, thereby ensuring that the yarns (S) pass through the passages 34 in a steady manner, and that the quality of dyeing is consistent.
[0100] 8. By virtue of the yarn separation temperature control unit 15 heating the yarn separation plate 14, the yarns (S) are heated by the yarn separation plate 14 and a heating surface area of the yarns (S) is increased. Thus, moisture in the yarns (S) may be completely removed, and the moisture content of each of the yarns (S) that enter the dyeing equipment 300 is standardized. When the yarns (S) are dry and fluffy, the yarns (S) absorb the ink more easily, and binding between the yarns (S) and the ink is increased, thereby improving the quality of dyeing.
[0101] 9. By virtue of the rounded surfaces 144 of the yarn separation plate 14, the textile auxiliary may slide off the rounded surfaces 144 into the separation grooves 142 when the textile auxiliary is sprayed on the yarn separation plate 14, which allows the yarns (S) that are in the separation grooves 142 to be more easily soaked in the textile auxiliary.
[0102] 10. By virtue of the orientation of the yarn arrangement plates 191 being adjustable, the distance between any two adjacent ones of the yarns (S) is adjustable to suit a width of the yarn separation roller 13 or a width of the yarn separation plate 14, thereby ensuring that the yarns (S) are evenly spaced and pass through the yarn separation roller 13 and the yarn separation plate 14 in parallel to each other.
[0103] 11. By virtue of the yarn winding equipment 500, the yarns (S) that have been heated for the dye fixation may be evenly separated and collected by the yarn winders 505, and may be directly supplied to small equipment or retailers for subsequent uses. The intricacy of the equipment and the space that all equipment has to occupy are reduced, thereby increasing the land use efficiency and reducing the cost of the equipment.
[0104] In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiment(s). It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. It should also be appreciated that reference throughout this specification to one embodiment, an embodiment, an embodiment with an indication of an ordinal number and so forth means that a particular feature, structure, or characteristic may be included in the practice of the disclosure. It should be further appreciated that in the description, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects; such does not mean that every one of these features needs to be practiced with the presence of all the other features. In other words, in any described embodiment, when implementation of one or more features or specific details does not affect implementation of another one or more features or specific details, said one or more features may be singled out and practiced alone without said another one or more features or specific details. It should be further noted that one or more features or specific details from one embodiment may be practiced together with one or more features or specific details from another embodiment, where appropriate, in the practice of the disclosure.
[0105] While the disclosure has been described in connection with what is (are) considered the exemplary embodiment(s), it is understood that this disclosure is not limited to the disclosed embodiment(s) but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.